Water-Cooled Scroll Compressor Chiller Group: Chillers IM ...€¦ · WGZ chillers are intended...

Installation and Maintenance Manual IM 1131

Water-Cooled Scroll Compressor Chiller Group: Chillers

Part Number: IM 1131 00

Date: March 2012

Supersedes: February 2012

© 2012 McQuay International

REV.

WGZ030DW - WGZ200DW, Packaged Water-Cooled Chillers

WGZ030DA - WGZ200DA, Condenserless Chillers

30 - 200 Tons (105 - 700 kW)

50/60 Hz

R-410A

2 IM 1131

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Piping Guidelines . . . . . . . . . . . . . . . . 5System Water Volume . . . . . . . . . . . . . . . . . . . 7Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Condenser Water Piping . . . . . . . . . . . . . . . . . 9

Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . 10Pressure Drop Data . . . . . . . . . . . . . . . . . . . . . . . . 14Dimensions - Packaged . . . . . . . . . . . . . . . . . . . . . 17Dimensions - Condenserless . . . . . . . . . . . . . . . . 21Lifting and Mounting Weights . . . . . . . . . . . . . . . . 26Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . 29Physical Data - Packaged Units . . . . . . . . . . . . . . 31Physical Data - Units Less Condenser . . . . . . . . . 34

Start-Up and Shutdown . . . . . . . . . . . . . . . . . . . . 36Start-Up and Shutdown . . . . . . . . . . . . . . . . . . . 36

Pre Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . 36Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Weekend or Temporary Shutdown . . . . . . . . 36

System Maintenance. . . . . . . . . . . . . . . . . . . . . . . 38Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 40System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . 42Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Electrical Notes . . . . . . . . . . . . . . . . . . . . . . . 43Units without Supplemental Overloads . . . . . 44Units with Supplemental Overloads . . . . . . . 44

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Warranty Registration Form (Scroll) . . . . . . . . . . 63

Hazard Identification

Note: Cover photograph is an WGZ060-D. This manual covers WGZ-D vintage water-cooled scroll chillers. For WGZ-C vintage models, see IMM WGZC, available at www.daikinmcquay.com.

DANGER

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

WARNING

Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.

CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

Document: IM 1131Issue Date: October 1, 2011Revision Date: March 14, 2012Replaces: October 1, 2011

Modbus

Manufactured in an ISO Certified facility

*AHRI Certification and ETL Listing apply to 60Hz models only

©2012 McQuay International. Illustrations and data cover the McQuay International product at the time of publication and we reserve the right to make changes in design and construction at anytime without notice. ™® The following are trademarks or registered trademarks of their respective companies: LEED is a registered trademark of the U.S. Green Building Council; BACnet from ASHRAE; LONMARK, LonTalk, LONWORKS, and the LONMARK logo are managed, granted and used by LONMARK International under a license granted by Echelon Corporation; Modbus from Schneider Electric; FanTrol, MicroTech II, Open Choice from McQuay International

http://www.mcquay.com


Introduction
Introduction
Chiller Nomenclature

General Description

Daikin McQuay WGZ water chillers are designed for indoor installations and are available with water-cooled condensers (Model WGZ-DW), or arranged for use with remote, air-cooled or evaporative condensers (Model WGZ-DA). Each water-cooled unit is completely assembled and factory wired before evacuation, charging and testing. They consist of hermetic scroll compressors, brazed-plate evaporators on Models WGZ 030 to 130 or shell-and-tube on Models WGZ 150 to 200, water-cooled condenser on Model WGZ-DW, and complete refrigerant piping.

Units manufactured for use with remote condensers (Models WGZ-DA) have all refrigerant specialties factory-mounted and connection points for refrigerant discharge and liquid lines.

Liquid line components that are included are manual liquid line shutoff valves, charging valves, filter-driers, liquid line solenoid valves, sight glass/moisture indicators, and expansion valves. Other features include compressor crankcase heaters, and a MicroTech II microprocessor controller.

The electrical control center includes all equipment protection and operating controls necessary for dependable automatic operation. Optional unit-mounted disconnect switche(s) may not be present, inwhich case a field-supplied and installed, fused disconnect switch is required. InspectionWhen the equipment is received, all items should be carefully checked against the bill of lading to be sure of a complete

shipment. All units must be carefully inspected for damage upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. The unit serial plate should be checked before unloading the unit to be sure that it agrees with the power supply available. Physical damage to unit after acceptance is not the responsibility of McQuay International.Note: Unit lifting weights and Corner operating weightsare given in the weight tables beginning on page 26.

Refrigerant ChargeEvery model WGZ-DW water chiller with water-cooled condensers is shipped with a full refrigerant charge. For shipment, the charge is contained in the condenser and is isolated by the condenser liquid shutoff valve and the compressor discharge valve common to a pair of compressors.

A holding charge of nitrogen/helium is supplied in remote condenser models, WGZ-DA and must be removed prior to charging with refrigerant. The operating charge must be field supplied and charged.

W G Z XXX D W

Water-Cooled

Global DesignScroll CompressorNominal Tons

Condenser

Design Vintage

W = Standard PackagedA = Less Condenser

CAUTION

If the unit is damaged, allowing the refrigerant to escape, there can be danger of suffocation in the area since the refrigerant will displace the

air. Be sure to review Environmental Protection Agency (EPA) requirements if damage occurs. Avoid exposing refrigerant to an open

flame.

IM 1131 3

Installation
Installation
InstallationNote: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment.

Location

WGZ chillers are intended only for installation in an indoor or weather protected area consistent with the NEMA 1 rating on the chiller, controls, and electrical panels. Equipment room temperature for operating and standby conditions is 40°F to 122°F (4.4°C to 50°C).

Because of the electrical control devices, the units should not be exposed to the weather. A plastic cover over the control box is supplied as temporary protection during shipment. A reasonably level and sufficiently strong floor is required for the water chiller. If necessary, additional structural members should be provided to transfer the weight of the unit to the nearest beams.

Space Requirements for Connections and Servicing

The chilled water and condenser water (on units with a water-cooled condenser) piping enters and leaves the unit from the right side when looking at the control panel. Left-hand condenser connections are an option. A clearance of at least 3 feet (1219 mm), or more if codes require, should be provided beyond this piping and on all other sides and ends of the unit for general servicing or for changing the compressors, if it ever becomes necessary. Allow a minimum of 4-foot clearance in front of the control panel or as required by the NEC or local codes.

On units equipped with a water-cooled condenser (Type WGZ-DW) clearance should also be provided for cleaning or removal of condenser tubes on one end of the unit. The clearance for cleaning depends on the type of apparatus used, but can be as much as the length of the condenser (10 feet, 3050 mm). Tube replacement requires the length of the condenser (as much as 12 feet) plus three feet of workspace.

This space can often be provided through a doorway or other opening.

Moving the Unit

Refer to Lifting/Mounting weights beginning on page 26.

The packaged unit skid option is strongly recommended for ease of handling and to help prevent damage if a crane is not available for rigging at site. Properly designed field supplied skids or dollies are acceptable. Do not push unit along a floor without them. The condenserless models (AGZ-DA) are manufactured with a base suitable for moving with rollers.

All moving and handling of packaged units (Figure 1) must be performed with skids or dollies under the unit and they should not be removed until the unit is in the final location. Never put the weight of the unit against the control box.

In moving, always apply pressure to the base on the skids only and not to the piping or other components. A long bar will help move the unit. Avoid dropping the unit at the end of the roll.

If the unit must be hoisted, lift the unit from the removable lifting arms factory-bolted to each end of the unit adjacent to the tube sheet by attaching cables or chains to the end of the arms. A spreader bar must be used to protect the piping, control panel and other areas of the chiller (Figure 1). The lifting arms should be removed and discarded after use.

Do not attach slings to piping or equipment. Do not attempt to lift the unit by lifting points mounted on the compressors. They are for lifting only the compressor should one need to be removed from the unit. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the truck or rollers.

Placing the Unit

The small amount of vibration normally encountered makes this unit particularly desirable for basement or ground floor installations where the unit can be mounted directly to the floor. The floor construction should be such that the unit will not affect the building structure, or transmit noise and vibration into the structure.

Figure 1: Lifting the Unit

CAUTION

Avoid contact with sharp edges. Personal injury can result

3319 26901 REV. 0 A

WGZ150-200CUNIT SHOWN

SPREADER BARS MUSTBE USED FOR STABILITY

DURING LIFTING OFALL SIZE UNITS

RemovableLiftingBar

(2) 2”LiftingHoles

4 IM 1131

Water Piping
Water Piping
Unit Configuration

WGZ 030DW to 130DW have two refrigerant circuits, two tandem scroll compressors (total of four), a single two-circuited brazed plate evaporator, a single two-circuited water-

cooled condenser, interconnecting refrigerant piping and a control panel with associated sensors and transducers. Models WGZ 150DW to 200DW have two trio-compressors (total of 6) and a shell-and-tube evaporator.

Figure 2: Schematic Piping Diagram (One of Two Circuits for Brazed Plate Evaporators)

Install Vessel Drain Plugs at Start-up

Condensers are drained of water in the factory and are shipped with the condenser drain plugs in the heads removed and stored in a bag in the control panel. Be sure to replace plugs prior to filling the vessel with fluid.

General Piping Guidelines

Due to the variety of piping practices, it is advisable to follow the recommendations of local authorities for code compliance. They can supply the installer with the proper building and safety codes required for a safe and proper installation.

The piping should be designed with a minimum number of bends and changes in elevation to keep system cost down and performance up. Other piping design considerations include:

1 All piping should be installed and supported to prevent the chiller connections from bearing any strain or weight of the system piping.

2 Vibration eliminators to reduce vibration and noise transmission to the building.

3 Shutoff valves to isolate the unit from the piping system during unit servicing.

4 Do not use PVC or CPVC piping for any water lines.

Comp#2

Comp#1

Condenser CondenserWater

EvaporatorChilledWater

S

F-D

T

S S

C V

SP

P1

LWT

T

T

Legend:

Temperature Sensor

Pressure Transducer

Pressure (High Pressure Cutout)

Temperataure Sensor, LeavingChilled Water Control

TT

TP

P1

LWT

Relief Valve

Schrader Fitting

Thermal Expansion Valve

Sight Glass / Moisture Indicator

Charging Valve

TS

C V

SSolenoid Valve

F-D Filter-Drier

Angle Valve

Ball Valve

NOTE: Standard condenserconnections are on the control panel end.

IM 1131 5

Water Piping

5 Manual or automatic air vent valves at the high points of the system. Drains should be placed at the lowest points in the system.

6 On units with factory-mounted flow switches and where flange connections (Victaulic-to-flange adaptors or weld-on flanges) are to be used, relocating the flow switch is required to allow for possible future replacement since the flange will interfere with unscrewing the switch. The following is recommended, before installing a flange, to avoid interference 1) Remove the flow switch before and plug the switch opening in the nozzle. 2) Install the Victaulic-to-flange adaptor or weld on flange. 3)Relocate the flow switch in the water piping outside the flange, close enough to it that the wire leads will reach and the switch can still be unscrewed.

7 Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating valve).

8 Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet of the vessels to aid in unit servicing.

9 This product is equipped with a copper-brazed 304 series stainless steel evaporator plate or a shell and tube evaporator with carbon steel shell and copper tubes. The water or other fluid used in these evaporators must be clean and non-corrosive to the materials used in the evaporator. The use of non-compatible fluids can void the equipment warranty. If the compatibility of the fluid with the evaporator is in question, a professional water quality consultant should administer the proper testing and evaluate compatibility

10 A strainer or some means of removing foreign matter from the water before it enters the pump is recommended. It should be placed far enough upstream

to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). The use of a strainer will prolong pump life and thus maintain system performance.

Important Note: A cleanable 40-mesh strainer must also be placed in the water line just prior to the inlet of the evaporator on Models WGZ 030 to 130. A 20-mesh is satisfactory on Models WGZ 150 to 200. This will aid in preventing foreign material from entering and decreasing the performance of the evaporator.

11 If the unit is used as a replacement chiller on a previously existing piping system, the system should be thoroughly flushed prior to unit installation. Regular water analysis and chemical water treatment on the evaporator and condenser is recommended immediately upon equipment start-up.

12 In the event glycol is added to the water system, as an afterthought for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop will be higher. If the percentage of glycol is large, or if propylene glycol is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set to default at 36°F (2.2°C). Reset the freezestat setting to approximately 4° to 5°F (2.3° to 2.8°C) below the leaving chilled water setpoint temperature. See the section titled "Glycol Solutions" for additional information concerning the use of glycol.

13 A preliminary leak check of the water piping should be made before filling the system.

Note: A water flow switch or pressure differential switch must be mounted in the evaporator outlet water line to signal that there is water flow before unit will start.

Figure 3: Typical Evaporator Field Water Piping (WGZ030 - WGZ130)

6 IM 1131

Water Piping

Figure 4: Typical Evaporator Field Water Piping (WGZ150 - WGZ200)

System Water Volume

It is important to have adequate water volume in the system to provide an opportunity for the chiller to sense a load change, adjust to the change, and then stabilize. The system water volume is the total amount of water in the evaporator, air handling equipment, and associated piping. As the expected load change becomes more rapid, a greater water volume is needed. If the water volume is too low, operational problems can occur including rapid compressor cycling, rapid loading and unloading of compressors, erratic refrigerant flow in the chiller, improper motor cooling, shortened equipment life and other undesirable occurrences.

For normal comfort cooling applications where the cooling load changes relatively slowly, a minimum system volume of two to three minutes times the flow rate (GPM) is recommended. For example, if the design chiller flow rate is 120 gpm, we recommend a system volume of 240 to 360 gallons.

For process applications where the cooling load can change rapidly, additional system water volume is needed. A process example would be the quenching of hot metal objects. The load would be very stable until the hot metal is dipped into the water tank. Then, the load would increase drastically.

Since there are many other factors that can influence performance, systems can successfully operate below these suggestions. But as the water volume decreases below these guidelines, the possibility of system instability increases.

Variable Chilled Water Flow

Reducing chilled water flow in proportion to load can reduce total system power consumption. Certain restrictions apply to the amount and rate of flow change. The rate of flow change should be a maximum of 10 percent of the change, per minute. Do not reduce flow lower than the part load minimum flows listed on page 14 or page 15.

Chilled Water Piping

The system water piping must be flushed thoroughly prior to making connections to the unit evaporator. It is required that a 40-mesh strainer be installed in the return water line before the

inlet to the chiller. Lay out the water piping so the chilled water circulating pump discharges into the evaporator inlet.

The return water line must be piped to the evaporator inlet connection and the supply water line must be piped to the evaporator outlet connection. If the evaporator water is piped in the reverse direction, a substantial decrease in capacity and efficiency of the unit will be experienced.

A flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water line to prove water flow before starting the unit.

Drain connections should be provided at all low points in the system to permit complete drainage of the system. Air vents should be located at the high points in the system to purge air out of the system. The evaporators are not equipped with vent or drain connections and provision must be made in the entering and leaving chilled water piping for venting and draining.

Pressure gauges should be installed in the inlet and outlet water lines to the evaporator. Pressure drop through the evaporator should be measured to determine water flow from the flow/pressure drop curves beginning on page 14. Vibration eliminators are recommended in both the supply and return water lines.

Chilled water piping should be insulated to reduce heat loss and prevent condensation. Complete unit and system leak tests should be performed prior to insulating the water piping. Insulation with a vapor barrier would be the recommended type of insulation. If the vessel is insulated, the vent and drain connections must extend beyond the proposed insulation thickness for accessibility.

Chillers not run in the winter should have their water systems thoroughly drained if subject to sub-freezing temperatures. If the chiller operates year-round, or if the system is not drained for the winter, the chilled water piping exposed to sub-freezing ambient temperatures should be protected against freezing by wrapping the lines with a heater cable. In addition, an adequate percentage of glycol should be added to the system to further protect the system during low ambient temperature periods. It should be noted that water piping that has been left drained is

Vent

Drain

GateValve

WaterStrainer

Vibrat ionEliminatorValved

PressureGauge

In

Out Protect All Field Piping Against Freezing

Flow

VibrationEliminator

FlowSwitch

BalancingValve

GateValve

Flow

Liquid

Suction

IM 1131 7

Water Piping

subject to more corrosion than if filled with water. Use of a Vapor Corrosion Inhibitor (VCI) or some other protection should be considered.

Figure 5: Thermostat Well Location, WGZ 030 - 130

The chilled water sensor is factory installed in the leaving water connection on the evaporator. Care should be taken not to damage the sensor cable or lead wires when working around the unit. It is also advisable to check the lead wire before running the unit to be sure that it is firmly anchored and not rubbing on the frame or any other component. If the sensor is ever removed from the well for servicing, care must be taken to not wipe off the heat-conducting compound supplied in the well.

Flow Switch

A water flow switch must be mounted in the leaving evaporator and condenser water lines to prove adequate water flow before the unit can start. This will safeguard against slugging the compressors on start-up. It also serves to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up. Factory-mounted and wired evaporator and condenser flow switches are available as an option

If the optional factory flow switch is not supplied, a flow switch is available from Daikin McQuay under part number 01750330. It is a "paddle" type switch and adaptable to any pipe size from 1 in. (25 mm) to 6 in. (152 mm) nominal. Certain flow rates are required to open the switch and are listed in Table 1. Wire from switch terminals Y and R to panel terminals 33 and 43 (chilled water) and 41 and 53 (condenser water). There is also a set of normally closed contacts on the switch that could be used for an indicator light or an alarm to indicate when a "no flow" condition exists.

1 Apply pipe sealing compound to only the threads of the switch and screw unit into 1 in. (25 mm) reducing tee. The flow arrow must be pointed in the correct direction.

2 Piping should provide a straight length before and after the flow switch of at least five times the pipe diameter without any valves, elbows, or other flow restricting elements.

Table 1: Paddle-Type Flow Switch Flow Rates

CAUTION

The thermostat bulb should not be exposed to water temperatures above 125°F (51.7°C) as this will damage it.

SuctionCircuit #1

SuctionCircuit #2

LiquidCircuit #2LiquidCircuit #1

Leaving ChilledWater Sensor

CAUTION

Make sure the arrow on the side of the switch is pointed in the direction of flow. The flow switch is designed to handle the control voltage and should be connected according to

the wiring diagram.

Pipe Size NOTES (x)

inch 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8mm 32 (2) 38 (2) 51 63 (3) 76 102 (4) 127 (4) 153 (4) 204 (5)

Min.Adjst.

Flowgpm 5.8 7.5 13.7 18.0 27.5 65.0 125.0 190.0 205.0Lpm 1.3 1.7 3.1 4.1 6.2 14.8 28.4 43.2 46.6

No Flowgpm 3.7 5.0 9.5 12.5 19.0 50.0 101.0 158.0 170.0Lpm 0.8 1.1 2.2 2.8 4.3 11.4 22.9 35.9 38.6

Max.Adjst.

Flowgpm 13.3 19.2 29.0 34.5 53.0 128.0 245.0 375.0 415.0Lpm 3.0 4.4 6.6 7.8 12.0 29.1 55.6 85.2 94.35455

No Flowgpm 12.5 18.0 27.0 32.0 50.0 122.0 235.0 360.0 400.0Lpm 2.8 4.1 6.1 7.3 11.4 27.7 53.4 81.8 90.8

Note (1): A segmented 3-inch paddle (1, 2, and 3 inches) is furnished mounted, plus a 6-inch paddle loose.Note (2): Flow rates for a 2-inch paddle trimmed to fit the pipe.Note (3): Flow rates for a 3-inch paddle trimmed to fit the pipe.Note (4): Flow rates for a 3-inch paddle.Note (5): Flow rates for a 6-inch paddle.

8 IM 1131

Water Piping

Glycol Solutions

WGZ units are designed to operate with a leaving chilled fluid temperature from 15°F (-9.4°C) to 60°F (16°C). Leaving chilled fluid temperatures below 40°F (4.6°C) result in suction temperatures at or below the freezing point of water and a glycol anti-freeze solution is required. The use of glycol in the evaporator will reduce the performance of the unit. The reduction in performance depends upon the glycol concentration and temperature. This should be taken into consideration during initial system design. Glycol in the condenser will have a negligible effect on performance because glycol at these higher temperatures will perform with characteristics similar to water.

Daikin McQuay recommends a minimum concentration of 25% be provided on all glycol applications. Glycol concentrations below 25% are too diluted for long-term corrosion protection of ferrous metals and corrosion inhibitors need to be recalculated and possibly added to the system.

Chiller capacity, flow rate, evaporator pressure drop, and power input for glycol solutions can be calculated using the following formulas and reference to Table 2 for ethylene glycol and Table 3 for propylene glycol. Test coolant with a clean, accurate, glycol solution hydrometer (similar to that found in service stations) to determine the freezing point.

Note: Ethylene and propylene glycol ratings are outside the scope of AHRI Standard 550/590-2003 certification program.

Capacity is reduced compared to that with plain water. To find the reduced value, multiply the chiller's capacity when using water by the capacity correction factor C to find the chiller's capacity when using glycol.

Flow -To determine evaporator gpm (or T) knowing T (or gpm) and capacity:

For Metric Applications -- Determine evaporator lps (or T) knowing T (or lps) and kW:

Pressure Drop - To determine glycol pressure drop through the cooler, enter the water pressure drop graph on page 14 at the actual glycol flow. Multiply the water pressure drop found there by P to obtain corrected glycol pressure drop.

Power -To determine glycol system kW, multiply the water system kW by factor K.

Table 2: Ethylene Glycol Correction Factors

Table 3: Propylene Glycol Correction Factors

Condenser Water PipingArrange the condenser water so the water enters the bottom connection of the condenser. The condenser water will discharge from the top connection. Failing to arrange the condenser water as stated above will negatively affect the capacity and efficiency.

Install pressure gauges in the inlet and outlet water lines to the condenser. Pressure drop through the condenser should be measured to determine flow on the pressure drop/flow curves beginning on page 14. Vibration eliminators are recommended in both the supply and return water lines. Install a 20-mesh strainer in the inlet piping to the condenser.

Water-cooled condensers can be piped for use with cooling towers, well water, or heat recovery applications. Cooling tower applications must be made with consideration of freeze protection and scaling problems. Contact the cooling tower manufacturer for equipment characteristics and limitations for the specific application. Head pressure control must be provided if the entering condenser water can fall below 60°F. The WGZ condenser has two refrigerant circuits with a common condenser water circuit. This arrangement makes head pressure control with discharge pressure actuated control valves difficult.

If the tower water temperature cannot be maintained at a 60°F minimum, or when pond, lake, or well water that can fall below 60°F (15°C) is used as the condensing medium, special discharge pressure control must be used. A water recirculating system with recirculating pump as shown in Figure 6 is recommended. This system also has the advantage of maintaining tube velocity to help prevent tube fouling. The pump must cycle with the chiller.Figure 6: Recirculating Discharge Water System

CAUTION

Do not use automotive antifreeze. Industrial glycols must be used. Automotive antifreeze contains inhibitors that causes plating on

copper tubes. The type and handling of glycol used must be consistent with local codes.

TablesFromGCorrectionFlowxT

CapacityGlycolxGPMGlycol

24

TablesfromGCorrectionFlowxTx

kWLpsGlycol

18.4

° F ° C10% 25.0 -3.9 0.997 0.999 1.030 1.113

20% 18.0 -7.8 0.993 0.997 1.060 1.226

30% 7.0 -14.0 0.987 0.995 1.092 1.369

40% -7.0 -22.0 0.980 0.992 1.132 1.557

50% -28.0 0.973 0.991 1.182 1.791

% E.G.Freeze Point Capacity

"C"Power

"K"Flow"G"

PD"P"

° F ° C10% 25.0 -3.9 0.994 0.998 1.016 1.10620% 19.0 -7.2 0.987 0.995 1.032 1.211

30% 9.0 -13.0 0.978 0.992 1.057 1.380

40% -5.0 -21.0 0.964 0.987 1.092 1.70350% -27.0 -32.8 0.952 0.983 1.140 2.250

Flow"G"

PD"P"

% P.G.Freeze Point Capacity

"C"Power

"K"

Circuit #1 Outlet

Condenser

TemperatureControlValve

CondenserWater

Circuit #2 Outlet

Circuit #1 Inlet

Circuit #2 Inlet

IM 1131 9

Refrigerant Piping
Refrigerant Piping
Refrigerant Piping

Refrigerant piping, to and from the unit, should be sized and installed according to the latest ASHRAE Handbook. It is important that the unit piping be properly supported with sound and vibration isolation between tubing and hanger, and that the discharge lines be looped at the condenser and trapped at the compressor to prevent refrigerant and oil from draining into the compressors. Looping the discharge line also provides greater line flexibility.

NOTE: Do not install any refrigerant piping underground.

The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and expansion valves are all factory mounted as standard equipment with the water chiller.

For remote condenser application (WGZ-DA) such as air-cooled or evaporative condenser, the chillers are shipped with a nitrogen/helium holding charge. The unit is evacuated in the factory to 500 microns before charging with the nitrogen.

The liquid line has a shutoff valve upstream from the liquid line solenoid valve and a copper tube cap to be brazed on this line after test to seal this line for shipment.

The discharge line has a ball valve installed between the compressor and the discharge stub tube with a copper tube cap brazed on the line after test to seal it for shipment.

The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and expansion valves are all factory-mounted as standard equipment with the water chiller.

It is important that the unit be kept tightly closed until the remote condenser is installed, piped to the unit and the high side evacuated.

When the field piping has been leak tested, evacuated, and is ready to charge, the unit valves can be opened and the system is ready to pressure test, evacuate and charge the entire system together at one time.

After the equipment is properly installed, leak tested, and evacuated, it can be charged with R-410A, and run at design load conditions. Add charge until the liquid line sight glass is clear, with no bubbles flowing to the expansion valve. Total operating charge will depend on the air-cooled condenser used and volume of the refrigerant piping.

NOTE: On WGZ-DA units (units with remote condensers), the installer is required to record the refrigerant charge by stamping the total charge and the charge per circuit on the serial plate in the appropriate blocks provided for this purpose.

Discharge lines must be designed to handle oil properly and to protect the compressor from damage that can result from condensing liquid refrigerant in the line during shutdown. Total friction loss for discharge lines of 3 to 6 psi (20.7 to 41.4 kPa) is considered good design. Careful consideration must be given for sizing each section of piping to insure that gas velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical discharge riser is too low, considerable oil can collect in the riser and the horizontal header, causing the compressor to lose its oil and result in damage due to lack of lubrication. When the compressor load is increased, the oil that had collected during reduced loads can be carried as a slug through the system and back to the compressor, where a sudden increase of oil concentration can cause liquid slugging and damage to the compressor.

Any horizontal run of discharge piping should be pitched away from the compressor approximately 1/8 inch (6.4 mm) per foot (meter) or more. This is necessary to move, by gravity, any oil lying in the header. Oil pockets must be avoided because oil needed in the compressor would collect at such points and the compressor crankcase can become starved.

It is recommended that any discharge lines coming into a horizontal discharge header rise above the centerline of the discharge header. This is necessary to prevent any oil or condensed liquid from draining to the compressor heads when the compressor is not running.

In designing liquid lines, it is important that the liquid reach the expansion valve without flash gas since this gas will reduce the capacity of the valve. Because "flashing" can be caused by a pressure drop in the liquid line, the pressure losses due to friction and changes in static head should be kept to a minimum.

A check valve must be installed in the liquid line in all applications where the ambient temperature can drop below the equipment room temperature. This prevents liquid migration to the condenser, helps maintain a supply of refrigerant in the liquid line for initial start-up, and keeps liquid line pressure high enough on "off" cycle to keep the expansion valve closed.

On systems as described above, a relief valve or relief-type check valve, must be used in the liquid line as shown in piping systems (shown in and Its purpose is to relieve dangerous hydraulic pressures that could be created as cool liquid refrigerant trapped in the line between the check valve and the expansion or shutoff valve warms up. Install a relief device in the hot gas piping at the condenser coil as shown in Figure 7 and Figure 8. Install a discharge check valve in the discharge line, in a horizontal run, close to the condenser.

DANGER

Do not apply heat, such as a brazing torch, to a sealed unit, vessel, or component. Internal gases can increase the internal pressure and cause a life-threatening explosion. Open the system when heating. The short line between a valve and brazed end cap can be drilled to vent it. Note that the valve may leak and the entire unit charge may be open to the cap.

10 IM 1131

Refrigerant Piping

Recommended Line Sizing for Field PipingFinal design should be based on ASHRAE design standards.

Table 4: Equivalent Feet for Fittings

Table 5: Maximum Line Size for Oil Carry Up a Discharge Riser, R-410A

Table 6: Recommended Liquid Line Size, R-410A

Fitting Type 7/8" 1 1/8" 1 3/8" 1 5/8" 2 1/8" 2 5/8" 3 1/8"

90º Standard 2.0 2.6 3.3 4.0 5.0 6.0 7.5

90º Long Radius 1.4 1.7 2.3 2.6 3.3 4.1 5.0

90º Street 3.2 4.1 5.6 6.3 8.2 10.0 12.0

45º Standard 0.9 1.3 1.7 2.1 2.6 3.2 4.0

45º Street 1.5 2.1 3.0 3.4 4.5 5.2 6.4

180º Bend 3.2 4.1 5.6 6.3 8.2 10.0 12.0

Full Size 1.4 1.7 2.3 2.6 3.3 4.1 5.0

Reducing 2.0 2.6 3.3 4.0 5.0 6.0 7.5

Globe Valve, Open 22.0 29.0 38.0 43.0 55.0 69.0 84.0

Gate Valve, Open 0.9 1.0 1.5 1.8 2.3 2.8 3.2

Angle Valve, Open 9.0 12.0 15.0 18.0 24.0 29.0 35.0

Valves

Elbows

Tees

Unit Size WGZ030 WGZ035 WGZ040 WGZ045 WGZ050 WGZ055 WGZ060 WGZ070 WGZ080 WGZ090

Line Size (in.) 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8

Unit Size WGZ100 WGZ115 WGZ130 WGZ150 WGZ170 WGZ200

Line Size (in.) 2 5/8 3 1/8 3 1/8 2 5/8 3 1/8 3 1/8

Up to Up to Up to Up to Up to

50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft 125 Equiv. Ft 150 Equiv. Ft

WGZ030 7/8" 7/8 " 7/8 " 7/8 " 7/8 " 7/8 "

WGZ035 7/8" 7/8 " 7/8 " 7/8 " 7/8 " 1 1/8 "

WGZ040 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "

WGZ045 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "

WGZ050 7/8" 7/8 " 7/8 " 7/8 " 1 1/8 " 1 1/8 "

WGZ055 7/8" 7/8 " 7/8 " 1 1/8” 1 1/8 " 1 1/8 "

WGZ060 7/8" 7/8 “ 7/8 " 1 1/8 " 1 1/8 " 1 1/8 "

WGZ070 1 1/8” 1 1/8” 1 1/8 " 1 1/8 " 1 1/8 " 1 1/8”

WGZ080 1 1/8” 1 1/8 " 1 1/8 " 1 1/8” 1 1/8” 1 1/8”

WGZ090 1 1/8” 1 1/8 " 1 1/8 " 1 1/8” 1 1/8” 1 1/8”

WGZ100 1 1/8” 1 1/8 " 1 1/8 " 1 1/8” 1 1/8” 1 1/8”

WGZ115 1 1/8” 1 1/8 " 1 1/8 " 1 1/8” 1 3/8” 1 3/8”

WGZ130 1 1/8” 1 1/8 " 1 3/8” 1 1/8” 1 3/8” 1 3/8”

WGZ150 1 3/8” 1 3/8” 1 1/8 " 1 3/8” 1 3/8” 1 3/8”

WGZ170 1 3/8” 1 3/8” 1 1/8 " 1 3/8” 1 3/8” 1 3/8”

WGZ-200 1 3/8” 1 3/8” 1 1/8 " 1 3/8” 1 3/8” 1 3/8”

Unit Model

Recommended Liquid Line Size (in.)Conn. Size

at Unit

IM 1131 11

Refrigerant Piping

Table 7: Recommended Horizontal or Downflow Discharge Line Size, R-410A

Typical Arrangements

Figure 7 illustrates a typical piping arrangement involving a remote air-cooled condenser located at a higher elevation than the compressor and receiver. This arrangement is commonly encountered when the air-cooled condenser is on a roof and the compressor and receiver are on grade level or in a basement equipment room.

Figure 8 illustrates another very common application where the air-cooled condenser is located on essentially the same level as the compressor and receiver. The discharge line piping in this case is not too critical. The principal problem encountered with this arrangement is that there is frequently

insufficient vertical distance to allow free drainage of liquid refrigerant from the condenser coil to the receiver.

Notice, in both illustrations, that the hot gas discharge line is looped at the bottom and top of the vertical run. This is done to prevent oil and condensed refrigerant from flowing back into the compressor and causing damage. The highest point in the discharge line should always be above the highest point in the condenser coil. It is advisable to include a purging vent at this point to extract non-condensables from the system.

The receiver is used when it is desired to have refrigerant storage capacity in addition to the pumpdown capability of the condenser.

Figure 7: Condenser Above Compressor and Optional Receiver Installation

Up to Up to Up to Up to Up to

50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft 125 Equiv. Ft 150 Equiv. Ft

WGZ030 1 3/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8" 1 1/8"

WGZ035 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ040 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ045 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ050 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ055 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8" 1 3/8"

WGZ060 1 3/8" 1 3/8" 1 5/8” 1 5/8” 1 5/8” 1 5/8”

WGZ070 1 3/8" 1 3/8" 1 5/8” 1 5/8” 1 5/8” 1 5/8”

WGZ080 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8”

WGZ090 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8”

WGZ100 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8” 1 5/8”

WGZ115 1 5/8” 1 5/8” 1 5/8” 2 1/8" 2 1/8" 2 1/8"

WGZ130 1 5/8” 1 5/8” 2 1/8" 2 1/8" 2 1/8" 2 1/8"

WGZ150 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8"

WGZ170 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8"

WGZ200 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 1/8" 2 5/8"

Unit Model

Recommended Discharge Line SizesConn. Size

at Unit

Condenser

Relief Valve

Check Valve

Purge Valve

Discharge Line

Loop

Receiver

Receiver Bypass

To Evap.

Preferred Subcooler Hook-up

Relief Valve (Vent to Outdoorsor to Condenser Sideof Liquid Line Check Valve)

Pitch

Check Valve

Subcooler

12 IM 1131

Refrigerant Piping

Figure 8: Condenser and Compressor on Same Level, Optional Receiver Installation Note: The receiver is bypassed during normal operation.

Receiver notes:1 The arrangement shown is required if the system

refrigerant charge exceeds the condenser coil pumpdown capacity.

2 This arrangement is used for head pressure control by adding a back-flooding valve.

3 When a receiver is not required, the refrigerant piping from the condenser outlet to the subcooler inlet is omitted. Flow is from the subcooling coil directly to the evaporator.

Factory-Mounted CondenserUnits with the standard water-cooled, factory-mounted condenser are provided with complete refrigerant piping and full operating refrigerant charge at the factory.

There is a remote possibility on water-cooled units utilizing low temperature pond or river water as a condensing medium, and if the water valves leak, that the condenser and liquid line refrigerant temperature could drop below the equipment room temperature on the "off" cycle. This problem only arises during periods when cold water continues to circulate through the condenser and the unit remains off due to satisfied cooling load.

If this condition occurs cycle the condenser pump off with the unit or check the liquid line solenoid valve for proper operation.

Relief Valve PipingThe ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems, specifies that pressure relief valves on vessels containing Group 1 refrigerant (R-410A) "shall discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the adjoining ground level and not less than 20 feet (6.1 meters) from any window, ventilation opening or exit in any building." The piping must be provided with a rain

cap at the outside terminating point and with a drain at the low point on the vent piping to prevent water buildup on the atmospheric side of the relief valve. Also, a flexible pipe section should be installed in the line to eliminate any piping stress on the relief valve(s).

The size of the discharge pipe from the pressure relief valve should not be less than the size of the pressure relief outlet. When two or more vessels are piped together, the common header and piping to the atmosphere should not be less than the sum of the area of each of the lines connected to the header.

NOTE: Fittings should be provided to permit vent piping to be easily disconnected for inspection or replacement of the relief valve.

Figure 9: Relief Valve Piping

The relief valve setting is 450 psi (3100 kPa) for water cooled and 600 psi (4175 kPa) for air-cooled applications.

Condenser

Re lief Va lve

Check Valve

Purge Valve

Relief Valve (Vent to O utdoors or to Condenser Side of Liquid Line Check Va lve )

Pitch

Check Valve

Discharge Line

Rece iver

Receiver Bypass

To Evap.

Preferred Subcoo ler Hook-up

Check V alve

Subcooler

Rain Cap

Vent

Wall Sleeve

Pinch To Outside

OutsideWall

15 ft Min. ClearanceTo Ground Level

(See Adjacent Information)

Flexible ConnectionInstall as close as possible

to Relief Valve

RefrigerantCondenser

Relief Valve

Inlet

Outlet

Drain forCondensation

IM 1131 13

Pressure Drop Data
Pressure Drop Data
Figure 10: WGZ-D Condenser Pressure Drop Curves

Table 8: WGZ-D CondenserPressure Drop Data

A

B

B

C

C

D

D

E

E

F

F

G

G

H

H

I

I

J

J

K

K

L

L

M

M

N

N

O

O

P

P

A

1

10

100

10 100 1000

Flow Rate (gpm)

Dp

(ft

)A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

GPM Ft L/S kPa GPM Ft L/S kPa GPM Ft L/S kPa

WGZ030D A 56.3 2.6 3.5 7.7 90.0 6.3 5.6 18.8 150.0 16.6 9.4 49.7

WGZ035D B 64.9 3.6 4.1 10.8 103.8 8.8 6.5 26.3 173.0 23.2 10.8 69.4

WGZ040D C 76.3 2.9 4.8 8.6 122.1 7.0 7.6 20.9 203.5 18.5 12.7 55.2

WGZ045D D 85.3 3.9 5.3 11.6 136.5 9.5 8.5 28.4 227.5 25.1 14.2 74.9

WGZ050D E 96.4 3.0 6.0 9.1 154.2 7.4 9.6 22.1 257.0 19.5 16.1 58.4

WGZ055D F 105.8 4.1 6.6 12.1 169.2 9.9 10.6 29.6 282.0 26.1 17.6 78.1

WGZ060D G 113.4 5.2 7.1 15.4 181.5 12.6 11.3 37.7 302.5 33.3 18.9 99.4

WGZ070D H 131.6 4.3 8.2 12.8 210.6 10.5 13.2 31.4 351.0 27.7 21.9 82.8

WGZ080D I 146.8 3.9 9.2 11.6 234.9 9.5 14.7 28.4 391.5 25.1 24.5 74.9

WGZ090D J 163.3 3.8 10.2 11.3 261.3 9.2 16.3 27.5 435.5 24.3 27.2 72.6

WGZ100D K 183.4 3.8 11.5 11.3 293.4 9.2 18.3 27.5 489.0 24.3 30.6 72.6

WGZ115D L 237.6 5.0 14.8 15.1 380.1 12.3 23.8 36.8 633.5 32.5 39.6 97.0

WGZ130D M 237.6 6.6 14.8 19.8 380.1 16.2 23.8 48.4 633.5 42.8 39.6 127.8

WGZ150D N 277.9 6.5 17.4 19.3 444.6 15.8 27.8 47.2 741.0 41.7 46.3 124.7

WGZ170D O 317.4 5.7 19.8 17.1 507.9 14.0 31.7 41.8 846.5 37.0 52.9 110.5

WGZ200D P 352.7 7.7 22.0 23.0 564.3 18.8 35.3 56.2 940.5 49.6 58.8 148.3

Curve Ref

Model Inch-Pound S.I.Minimum Flow & Pr. Drop Nominal Flow & Pr. Drop Maximum Flow & Pr. DropInch-Pound Inch-PoundS.I. S.I.

14 IM 1131

Pressure Drop Data

Figure 11: WGZ-D Evaporator Pressure Drop Curves

Table 9: WGZ-D Evaporator Pressure Drop Data

AB

B

C

C

D

D

E

E

F

F

G

G

H

H

I

I

J

J

K

K

L

L

M

M

N

N

O

O

P

P

A

1

10

100

10 100 1000

Flow Rate (gpm)

Dp

(ft

)

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

GPM Ft L/S kPa GPM Ft L/S kPa GPM Ft L/S kPa

WGZ030D A 45.0 4.9 2.8 14.7 72.0 12.0 4.5 35.9 120.0 31.7 7.5 94.7

WGZ035D B 51.9 5.4 3.2 16.3 83.0 13.3 5.2 39.8 138.3 35.1 8.6 104.9

WGZ040D C 61.1 6.3 3.8 19.0 97.7 15.5 6.1 46.3 162.8 40.9 10.2 122.3

WGZ045D D 68.3 6.0 4.3 18.0 109.2 14.7 6.8 43.9 182.0 38.8 11.4 116.0

WGZ050D E 77.1 6.1 4.8 18.2 123.4 14.9 7.7 44.5 205.7 39.3 12.9 117.6

WGZ055D F 84.6 6.5 5.3 19.3 135.4 15.8 8.5 47.2 225.7 41.7 14.1 124.7

WGZ060D G 90.8 5.9 5.7 17.7 145.2 14.5 9.1 43.3 242.0 38.3 15.1 114.4

WGZ070D H 105.3 6.5 6.6 19.3 168.5 15.8 10.5 47.2 280.8 41.7 17.6 124.7

WGZ080D I 117.4 4.9 7.3 14.7 187.9 12.0 11.7 35.9 313.2 31.7 19.6 94.7

WGZ090D J 130.6 5.2 8.2 15.7 209.0 12.8 13.1 38.3 348.3 33.8 21.8 101.0

WGZ100D K 146.7 4.8 9.2 14.4 234.7 11.8 14.7 35.3 391.2 31.1 24.4 93.1

WGZ115D L 169.4 5.0 10.6 15.1 271.0 12.3 16.9 36.8 451.7 32.5 28.2 97.0

WGZ130D M 190.1 5.3 11.9 15.9 304.1 13.0 19.0 38.9 506.8 34.3 31.7 102.6

WGZ150D N 222.3 6.2 13.9 18.6 355.7 15.2 22.2 45.4 592.8 40.1 37.1 119.9

WGZ170D O 253.9 7.4 15.9 22.0 406.3 18.0 25.4 53.8 677.2 47.5 42.3 142.0

WGZ200D P 282.1 9.0 17.6 26.9 451.4 22.0 28.2 65.8 752.3 58.1 47.0 173.6

Nominal Flow & Pr. Drop Maximum Flow & Pr. DropCurve Ref S.I. Inch-Pound S.I.Inch-Pound Inch-PoundS.I.Model

Minimum Flow & Pr. Drop

IM 1131 15

Pressure Drop Data

16 IM 1131

Dimensions - Packaged
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IM 1131 17


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OLE

S (4

)73

7

2.0 51

36.9

EVA

PIN

LET/

OU

TLET

938

13.3

337

35.8

908

ZPO

WER

CON

NEC

TIO

NS

.88

KNO

CKO

UTS

REM

OVA

BLE

DIS

C. H

AN

DLE

CON

TRO

LCO

NN

ECTI

ON

S.8

8 KN

OCK

OU

TSO

N O

PPO

SITE

SID

E

REM

OVE

BRK

T.FO

R SH

IPPI

NG

ON

LY

1.3 34

23.5

596

77.2

1961

EVA

PORA

TOR

OU

TLET

EVA

PORA

TOR

INLE

T

CERT

IFIE

D, W

GZ1

50-2

00D

1

2

OF

*333

6117

0100

1*

20 IM 1131

Dimensions - Condenserless
Figure 16: WGZ030DA - 060DA (Condenserless)

12.3

312

137.

034

80

6.0

152

20.2

512

X

Y

MIC

ROTE

CH II

USE

R IN

TERF

ACE

CIRC

UIT

1CI

RCU

IT 2

20.0

508

9.0

229

40.0

1016

34.0

864

6.1

155

2.5 64

5.9

LIQ

UID

CON

NEC

TIO

NS

150 16

.5

EVA

P. A

ND

DIS

CHA

RGE

CON

NEC

TIO

NS

419

60.0

1524

30.0

ISO

LATO

R H

OLE

S (4

)76

2

2.0 51

30.4

772

2.0 51

23.5

597

Z

CON

TRO

L CO

NN

ECTI

ON

.88

DIA

. KN

OCK

OU

TSO

N O

PPO

SITE

SID

EEV

APO

RATO

R

REM

OVE

BRK

T.FO

R SH

IPPI

NG

ON

LY

INLE

T

OU

TLET

POW

ERCO

NN

ECTI

ON

S.8

8" D

IA. K

NO

CKO

UTS

REM

OVA

BLE

DIS

C. H

AN

DLE

A

31.4

798

38.2

970

91.9

2334

98.8

2509

7.0

177

10.2

258

41.3

1050

26.8

681

INLE

T

OU

TLET

.88

LIQ

UID

CON

NEC

TIO

NS

1.38

DIS

CHA

RGE

CON

NEC

TIO

NS

CERT

., W

GZ0

30-0

60D

, LES

S CO

ND

*333

6115

1100

1* p

1/1

IM 1131 21


Figure 17: WGZ070DA (Condenserless)

137.

034

80

23.2

588

6.0

152

12.3

312

7.0

178

2.2 57

71.0

1804

28.5

724

REM

OVA

BLE

BRA

CKET

MIC

ROTE

CH II

U

SER

INTE

RFA

CECI

RCU

IT 1

CIRC

UIT

2

CG

4.0

101

40.0

1016

1.5 38

34.0

864

15.5

394

30.0

ISO

LATO

R H

OLE

S (4

)76

2

2.0 51

9.0

229

6.1

155

20.0

508

60.0

1524

32.4

823

40.1

1017

2.0 51

23.5

597

15.3

388

CON

TRO

LCO

NN

ECTI

ON

S.8

8 KN

OCK

OU

TSO

N O

PPO

SITE

SID

E

POW

ERCO

NN

ECTI

ON

S.8

8 KN

OCK

OU

TS

EVA

PORA

TOR

INLE

T

OU

TLET

REM

OVE

BRA

CKET

.FO

R SH

IPPI

NG

ON

LY

LIQ

UID

CON

NEC

T-IO

NS

REM

OVA

BLE

DIS

C. H

AN

DLE

CG

EVA

P. A

ND

DIS

CHA

RGE

CON

NEC

TIO

NS

38.2

970

13.3

338

98.7

2507

25.9

659

96.7

2457

9.1

231

19.2

489

28.6

725

50.9

1293

1.38

DIS

CHA

RGE

CON

NEC

TIO

NS

1.13

LIQ

UID

CO

NN

ECTI

ON

S

INLE

T

OU

TLET

WG

Z070

D

CERT

. WG

Z070

-130

D, L

ESS

CON

D*3

3361

1611

001*

1/3

22 IM 1131


Figure 18: WGZ080DA - 130DA (Condenserless)

137.

034

80

23.2

588

6.0

152

5.0

126

12.3

312

7.0

178

X

YRE

MO

VABL

EBR

ACK

ET

MIC

ROTE

CH II

U

SER

INTE

RFA

CE

CIRC

UIT

1CI

RCU

IT 2

4.0

101

40.0

1016

1.5 38

34.0

864

15.5

394

30.0

ISO

LATO

R H

OLE

S (4

)76

2

2.0 51

60.0

1524

20.0

508

9.0

229

6.1

155

32.4

823

40.1

1017

2.0 51

23.5

597

Z

CON

TRO

LCO

NN

ECTI

ON

S.8

8 KN

OCK

OU

TSO

N O

PPO

SITE

SID

E

POW

ERCO

NN

ECTI

ON

S.8

8 KN

OCK

OU

TS

EVA

PORA

TOR

INLE

T

OU

TLET

REM

OVE

BRA

CKET

.FO

R SH

IPPI

NG

ON

LY

LIQ

UID

CON

NEC

T-IO

NS

REM

OVA

BLE

DIS

C. H

AN

DLE

EVA

PORA

TOR

&D

ISCH

ARG

ECO

NN

ECTI

ON

S

38.2

971

13.3

338

98.8

2509

26.0

659

96.7

2455

7.4

187

"A"

28.6

725

50.9

1293

7.4

187

DIS

CHA

RGE

CON

NEC

TIO

NS

"B"

LIQ

UID

CO

NN

ECTI

ON

S "C

"

OU

TLET

INLE

T

WG

Z080

-130

D

CERT

. WG

Z070

-130

D, L

ESS

CON

D*3

3361

1611

002*

2/3

IM 1131 23


Figure 19: WGZ150DA - 200DA (Condenserless) (see next page for more dimensions)

154.

039

12

1.9 48

Y

X

CIRC

UIT

1CI

RCU

IT 2

MIC

ROTE

CH II

USE

R IN

TERF

ACE

74.9

1903

40.0

1016

34.0

864

4.0

LIQ

UID

CON

NEC

TIO

NS

101

30.0

ISO

LATO

R H

OLE

S (6

)76

22.

0 51

20.0

508

9.0

229

5.0

127

2.9 74

40.5

1029

2.0 51

23.5

597

Z

REM

OVA

BLE

DIS

C. H

AN

DLE

POW

ERCO

NN

ECTI

ON

S.8

8 KN

OCK

OU

TS(Q

TY. 3

)

CON

TRO

LCO

NN

ECTI

ON

S.8

8 KN

OCK

OU

TSO

N O

PPO

SITE

SID

E

REM

OVE

BRK

T.FO

R SH

IPPI

NG

ON

LY

CERT

. WG

Z150

-200

D, L

ESS

CON

D.

*333

6117

1100

1*

24 IM 1131


Figure 20: WGZ150DA - 200DA (Condenserless) (continued)

23.2

588

6.0

152

42.1

1069

119.

330

30

70.7

1796

20.9

530

34.2

867

17.4

443

34.0

863

96.2

2443IN

LET

OU

TLET

2.12

O.D

. DIS

CHA

RGE

CON

NEC

TIO

NS

1.38

O.D

. LIQ

UID

CON

NEC

TIO

NS

CIRC

UIT

1CI

RCU

IT 2

3.6

EVA

PORA

TOR

INLE

T/O

UTL

ET

90

2.3

DIS

CHA

RGE

CIRC

UIT

1

597.

9

DIS

CHA

RGE

CIRU

CIT

2

200

12.1

307

13.5

343

CERT

. WG

Z150

-200

D, L

ESS

CON

D.

*333

6117

1100

2* 2

/3

IM 1131 25

Lifting and Mounting Weights
Figure 21: Lifting Locations, WGZ030-060D Packaged

Table 10: Lifting Weights, WGZ030-060D Packaged



L1/M1 L2/M2

L3/M3L4/M4

CONTROL BOX

WATERCONNECTIONS

L1 L2 L3 L4 M1 M2 M3 M4

605 632 598 572 624 652 617 590 2408 2484(274) (287) (271) (259) (283) (296) (280) (268) (1092) (11127)629 644 614 601 649 664 633 619 2488 2564

(285) (292) (279) (273) (294) (301) (287) (281) (1129) (1163)634 656 627 606 657 680 650 628 2523 2615

(288) (298) (284) (275) (298) (308) (295) (285) (1144) (1186)634 664 635 606 657 688 658 628 2539 2631

(288) (301) (288) (275) (298) (312) (299) (285) (1152) (1193)646 683 656 621 674 713 685 648 2606 2719

(293) (310) (298) (282) (306) (323) (311) (294) (1182) (1233)644 690 664 620 672 720 693 647 2618 2731

(292) (313) (301) (281) (305) (327) (314) (293) (1188) (1239)646 706 682 624 674 736 711 651 2658 2771

(293) (320) (309) (283) (306) (334) (323) (295) (1206) (1257)

OPER. WTLBS (KG)

SHIP WTLBS (KG)

WGZ055DW

WGZ060DW

WGZ035DW

WGZ040DW

WGZ045DW

WGZ050DW

MODELLIFTING WEIGHT FOR EACH POINT LBS (KG) MOUNTING LOADS FOR EACH POINT LBS (KG)

WGZ030DW

CONTROL BOX

WATERCONNECTIONS

L3/M3

L2/M2L1/M1

L4/M4

CERTIFIED, WGZ070-130D*333611601003* p3/3

L1 L2 L3 L4 M1 M2 M3 M4

877 843 900 935 912 877 935 973 3555 3696(398) (382) (408) (424) (414) (398) (424) (441) (1613) (1676)1016 900 965 1090 1056 935 1003 1133 3971 4128(461) (408) (438) (494) (479) (424) (455) (514) (1801) (1872)1026 824 1020 1270 1071 860 1064 1325 4140 4320(465) (374) (463) (576) (486) (390) (483) (601) (1878) (1960)1018 763 1084 1446 1066 799 1135 1515 4311 4515(462) (346) (492) (656) (484) (362) (515) (687) (1955) (2048)984 769 1087 1390 1032 806 1139 1457 4230 4434

(446) (349) (493) (630) (468) (366) (517) (661) (1919) (2011)1046 824 1173 1490 1093 861 1226 1557 4533 4737(475) (374) (532) (676) (496) (391) (556) (706) (2056) (2149)

SHIP WTLBS (KG)

OPER. WTLBS (KG)

WGZ100DW

WGZ115DW

WGZ130DW

MOUNTING LOADS FOR EACH POINT LBS (KG)

WGZ070DW

WGZ080DW

WGZ090DW

MODWELLIFTING WEIGHT FOR EACH POINT LBS (KG)

26 IM 1131




Figure 24: Lifting Locations, WGZ030-060D Condenserless

Table 13: Lifting Weights, WGZ030-060D Condenserless

EVAP. OUTLET EVAP. INLET

CONTROL BOX

WATERCONNECTIONS

L4/M4

L1/M1

L3/M3

L2/M2

L1 L2 L3 L4 M1 M2 M3 M4

1490 1393 1444 1545 1691 1581 1638 1752 5873 6662(676) (632) (655) (701) (767) (717) (743) (795) (2664) (3022)1661 1439 1521 1756 1880 1628 1720 1986 6377 7214(753) (653) (690) (797) (853) (738) (780) (901) (2893) (3272)1729 1492 1599 1852 1946 1679 1799 2085 6672 7509(784) (677) (725) (840) (883) (762) (816) (946) (3026) (3406)

WGZ150DW

WGZ170DW

WGZ200DW

MODWELLIFTING WEIGHT FOR EACH POINT LBS (KG) MOUNTING LOADS FOR EACH POINT LBS (KG) SHIP WT

LBS (KG)OPER. WTLBS (KG)

21.0533

95.02413

21.05332.0

51

30.0762

2.051

.75

ISOLATOR HOLES ARE INTHE BOTTOM OF THE BASE

19

CONTROL BOX

EVAP. WATERCONNECTIONS

CIRCUIT 1CIRCUIT 2

L4

L1

M4

M1 M2 L2

L3M3

WGZ030-060D, LESS COND*333611511002* p 2 of 2

L1 L2 L3 L4 M1 M2 M3 M4

415 430 373 360 476 501 322 306 1578 1604(188) (195) (169) (163) (216) (227) (146) (139) (716) (728)

440 444 391 387 508 515 336 331 1662 1690(200) (201) (177) (176) (230) (234) (152) (150) (754) (767)

435 446 399 389 502 521 345 332 1669 1699(197) (202) (181) (176) (228) (236) (156) (151) (757) (771)

435 454 406 389 501 533 353 332 1685 1719(197) (206) (184) (176) (227) (242) (160) (151) (764) (780)

437 460 413 392 503 542 361 335 1702 1740(198) (209) (187) (178) (228) (246) (164) (152) (772) (789)

435 467 420 392 500 553 369 333 1714 1755(197) (212) (191) (178) (227) (251) (167) (151) (778) (796)

438 475 431 397 503 565 380 338 1741 1786(199) (216) (196) (180) (228) (256) (172) (153) (790) (810)

SHIP WTLBS (KG)

OPER. WTLBS (KG)

WGZ060DA

WGZ040DA

WGZ045DA

WGZ050DA

WGZ055DA

LIFTING WEIGHT FOR EACH POINT LBS (KG) MOUNTING LOADS FOR EACH POINT LBS (KG)

WGZ030DA

WGZ035DA

MODEL

IM 1131 27






.75

ISOLATOR HOLES IN THEBOTTOM OF THE BASE

19

21.0533

95.02413

21.0533

30.0762

2.051

2.051

CIRCUIT 1CIRCUIT 2

EVAP. WATERCONNECTIONS

CONTROL BOX

L4

L1 L2

L3

M1 M2

M3M4

CERT. WGZ070-130D, LESS COND*333611611003*

L1 L2 L3 L4 M1 M2 M3 M4

431 503 552 472 565 700 571 461 1958 2296(196) (228) (250) (214) (256) (318) (259) (209) (888) (1041)

600 631 691 657 705 755 615 575 2579 2649(272) (286) (313) (298) (320) (343) (279) (261) (1170) (1202)

630 651 722 699 743 778 643 614 2701 2778(286) (295) (328) (317) (337) (353) (292) (279) (1225) (1260)

658 684 764 735 777 820 681 646 2841 2923(299) (310) (347) (333) (352) (372) (309) (293) (1289) (1326)

617 681 784 710 722 828 709 619 2792 2878(280) (309) (356) (322) (328) (376) (322) (281) (1266) (1305)

705 764 845 780 828 925 761 682 3094 3196(320) (347) (383) (354) (376) (420) (345) (309) (1403) (1450)

SHIP WTLBS (KG)

OPER. WTLBS (KG)

WGZ115DA

WGZ130DA

WGZ070DA

WGZ080DA

WGZ090DA

WGZ100DA

MODELLIFTING WEIGHT FOR EACH POINT LBS (KG) MOUNTING LOADS FOR EACH POINT LBS (KG)

21.0533

54.01372

58.01473

21.0533

2.051

2.051

30.0762

.75

ISOLATOR HOLES IN THEBOTTOM OF THE BASE

19

M1L1 L2M2 M3

L3M4

L4M5M6

CONTROL BOX

CIRCUIT 1CIRCUIT 2

CERT. WGZ150-200D, LESS COND.

*333611711003* 3/3

L1 L2 L3 L4 M1 M2 M3 M4 M5 M6

912 952 1127 1080 671 713 758 860 809 761 4071 4571(414) (432) (511) (490) (304) (323) (344) (390) (367) (345) (1847) (2073)

1003 994 1170 1180 747 754 760 868 860 853 4347 4841(455) (451) (531) (535) (339) (342) (345) (394) (390) (387) (1972) (2196)

1090 1065 1228 1257 796 791 785 914 921 927 4640 5134(494) (483) (557) (570) (361) (359) (356) (415) (418) (421) (2105) (2329)

SHIP WTLBS (KG)

OPER. WTLBS (KG)

MOUNTING LOADS FOR EACH POINT LBS (KG)

WGZ150DA

WGZ170DA

WGZ200DA

MODELLIFTING WEIGHT FOR EACH POINT (LBS)

28 IM 1131

Vibration Isolators
Vibration Isolators
It is recommended that isolators be used on all upper level installations or in areas where vibration transmission is a consideration.

Figure 27: Isolator Locations

Transfer the unit as indicated under "Moving the Unit." In all cases, set the unit in place and level with a spirit level. When spring-type isolators are required, install springs running under the main unit supports.

The unit should be set initially on shims or blocks at the listed spring free height. When all piping, wiring, flushing, charging, etc., is completed, the springs are adjusted upward to loosen the blocks or shims that are then removed.

A rubber anti-skid pad should be used under isolators if hold-down bolts are not used.

Installation of spring isolators requires flexible piping connections and at least three feet of flexible electrical conduit to avoid straining piping and transmitting vibration and noise.

Refer to unit dimension drawing for mounting locations.

Table 16: Isolator Kit Part Numbers

Table 17: Vibration Isolator Mounting Locations (Packaged Chillers)

Control Panel

WaterConnections

4

1

3

2

LB

LF

RB

FRF

WGZ-DW Packaged Chiller Isolator Kit Part NumbersModel Number 030-060 070-080 90 100-130 150-200

Spring-Flex 332320501 332320502 332320503 332320504 332320505

R-I-S 332325501 332325502 332325502 332325503 332325503

WGZ-DA Remote Condenser Isolator Kit Part NumbersModel Number 030-060 070-080 090-115 130 150-200

Spring-Flex 332320506 332320507 332320508 332320509 332320510

R-I-S 332325504 332325501 332325501 332325501 332325505

Unit

Size M1 M2 M3 M4 M1 M2 M3 M4

ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3

Green Green Green Green Gray Gray Gray Gray














Purple Purple Purple Purple Brow n Brow n Brow n Brow n


Purple Purple Purple Purple Brow n Brow n Brow n Brow n


Green Green Green Green Brow n Brow n Brow n Brow n


Green Green Green Gray Brick Red Brick Red Brick Red Brick Red

WGZ040DW

WGZ035DW

Spring-Flex Mountings R-I-S Mountings

WGZ030DW

WGZ055DW

WGZ050DW

WGZ045DW

WGZ100DW

WGZ090DW

WGZ080DW

WGZ070DW

WGZ060DW

IM 1131 29

Vibration Isolators

Table 18: Vibration Isolator Mounting Locations (Packaged Chillers), continued

Table 19: Vibration Isolator Mounting Locations (Condenserless Chillers)

Unit

Size M1 M2 M3 M4 M1 M2 M3 M4






Gray Gray Gray Gray Brick Red Brick Red Brick Red Brick Red





Spring-Flex Mountings R-I-S Mountings

WGZ170DW

WGZ150DW

WGZ130DW

WGZ115DW

WGZ200DW

Unit

Size M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6

ID-900 ID-900 ID-510 ID-510 N/A N/A RP-3 RP-3 RP-3 RP-3 N/A N/A

Green Green Black Black Lime Lime Lime Lime













ID-900 ID-900 ID-675 ID-900 N/A N/A RP3 RP3 RP3 RP3 N/A N/A

Green Green Purple Green Gray Gray Gray Gray


Green Green Purple Green Gray Gray Gray Gray


Black Black Red Black Gray Gray Gray Gray







ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 ID-1020 RP-4 RP-4 RP-4 RP-4 RP-4 RP-4

Black Black Black Black Black Black Brow n Brow n Brow n Brow n Brow n Brow n





WGZ060DA

WGZ055DA

R-I-S Mountings

WGZ030DA

WGZ035DA

WGZ040DA

WGZ070DA

Spring-Flex Mountings

WGZ045DA

WGZ050DA

WGZ115DA

WGZ100DA

WGZ090DA

WGZ080DA

WGZ200DA

WGZ170DA

WGZ150DA

WGZ130DA

30 IM 1131

Physical Data - Packaged Units
Table 20: Physical Data - WGZ030D - WGZ055D

Note 1: Capacity certified in accordance with AHRI Standard 550/590.Note 2: 90% Full R-410A at 90°F (32°C)

WGZ UNIT SIZE

Unit capacity @ AHRI tons, (kW) (Note 1)

No. Circuits

COMPRESSORSNominal Tons 7.5 7.5 9 9 10 10 12 12 13 13 13 15Number Per Circuit 2 2 2 2 2 2 2 2 2 2 2 2

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENTStaging, Circuit #1 in Lead

Staging, Circuit #2 in Lead

Oil Charge per Compressor- oz. (l)

CONDENSERNumber

No. Refrigerant Circuits

Diameter- in. (mm)

Tube Length- in. (mm)

Design Working Pressure PSIG, (kPa): Refrigerant Side Water SidePump-Out Capacity- lb. (kg) (Note 2)

Victaulic Conn.In & Out- in. (mm)

Relief Valve, Flare- In. (mm)

Purge Valve, Flare- In. (mm)

Vent & Drain- in. (mm) NPT

Liquid Subcooling

EVAPORATOR, BRAZED-PLATENumberNo. Refrigerant Circuits

Water Volume- gal (l)Design Working Pressure- PSIG, (kPa): Refrigerant Side Water Side Victaulic Conn. In & Out- in. (mm) Relief Valve, Flare- in. (mm)Vent & Drain

UNIT DIMENSIONSLength- in. (mm)Width- in. (mm)Height- in. (mm)

UNIT WEIGHTSOperating Weight- lb. (kg)Shipping Weight- lb. (kg)Cir #1 R410A Oper Charge- lb. (kg) Cir #2 R410A Oper Charge- lb. (kg)

653 (4500)2.5 (65)

653 (4500)

2.6 (9.8)

32.8 (832)

Integral Integral Integral Integral

5/8 (15.9) 5/8 (15.9) 5/8 (15.9)

136.0 (3455)

47 (21.4) 50 (22.7)

22

43 (19.5) 43 (19.5) 43 (19.5)

2488 (1129) 2523 (1144)

47 (21.4)

2606 (1182) 2618 (1188)43 (19.5) 43 (19.5) 43 (19.5) 47 (21.4) 47 (21.4) 50 (22.7)

2408 (1092) 2539 (1152)2484 (1127) 2564 (1163) 2615 (1186) 2631 (1193) 2731 (1239)

63.4 (1609)32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832)63.4 (1609) 63.4 (1609) 63.4 (1609) 63.4 (1609)

32.8 (832)136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455) 136.0 (3455)

5/8 (15.9) 5/8 (15.9)Field Field Field Field Field Field

5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9)

653 (4500)653 (4500)2.5 (65)2.5 (65) 2.5 (65) 2.5 (65) 2.5 (65)

653 (4500) 653 (4500) 653 (4500)653 (4500)653 (4500)653 (4500) 653 (4500) 653 (4500)

2.3 (8.7)

2 2 22

1.6 (6.1) 1.8 (6.8) 2.0 (7.6) 2.8 (10.6)

21

Integral

1 12

1/4 (6.4) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4)

1 1 1

4 (102)

5/8 (15.9) 5/8 (15.9)

1/4 (6.4) 1/4 (6.4)

1/2 (12.7)

5/8 (15.9)

1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)

4 (102) 4 (102) 4 (102) 4 (102)

205.4 (93.4)232 (1599) 232 (1599)

245.8 (111.7) 245.8 (111.7) 228.2 (103.7) 228.2 (103.7)232 (1599) 232 (1599)

120 (3048)

232 (1599) 232 (1599)

120 (3048) 120 (3048)

500 (3447) 500 (3447)500 (3447) 500 (3447) 500 (3447) 500 (3447)

120 (3048) 120 (3048) 120 (3048)

2

10 (254) 10 (254) 10 (254) 10 (254) 10 (254) 10 (254)

2 2 2

1

85 (2.5)

1 1 1 1

110 (3.3) 110 (3.3) 110 (3.3)27 / 50 / 77 / 10025 / 50 / 75 / 100 25 / 50 / 75 / 100

110 (3.3)

25 / 50 / 75 / 100 25 / 50 / 75 / 100

25 / 50 / 75 / 100 25 / 50 / 75 / 100

25 / 50 / 75 / 100 25 / 50 / 75 / 100

2

25 / 50 / 75 / 100 23 / 50 / 73 / 100

2 2 2 2

56.4 (198.3)

030 035

30.0 (105.5) 34.6 (121.7) 40.7 (143.1) 45.5 (160.0)

040 045 055

51.4 (180.7)

1

Integral

63.4 (1609)

2719 (1233)

050

2

25 / 50 / 75 / 100110 (3.3)

205.4 (93.4)

1/2 (12.7)

4 (102)

IM 1131 31




WGZ UNIT SIZE

Unit capacity @ AHRI tons, (kW) (Note 1)

No. Circuits

COMPRESSORSNominal Tons 15 15 15/20 15/20 20 20 20/26 20/26 26 26Number per Circuit4 2 2 2 2 2 2 2 2 2 2CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT

Staging, 4 Stages, Circuit #1 in Lead

Staging, 4 Stages, Circuit #2 in Lead

110 (3.3) 110 (3.3)

145 (4.3) 145 (4.3)

CONDENSERNumberNo. Refrigerant Circuits

Diameter, in. (mm)

Tube Length, in. (mm)

Design Working Pressure, psig (kPa): Refrigerant Side Water SidePump-Out Capacity- lb. (kg) (Note 2)

Conn. In & Out, in., (mm) VictaulicRelief Valve, Flare in., (mm)Purge Valve, Flare in. (mm)

Vent & Drain, in. (mm) NPT

Liquid Subcooling

EVAPORATOR, BRAZED-PLATENumber

No. Refrigerant CircuitsWater Volume- gal (l)Design Working Pressure- PSIG, (kPa): Refrigerant Side Water Side Victaulic Conn. In & Out- in. (mm) Relief Valve, Flare- in. (mm)Vent & Drain


UNIT WEIGHTSOperating Weight- lb. (kg)Shipping Weight- lb. (kg)Cir #1 R410A Oper Charge- lb. (kg)

145 (4.3)145 (4.3)

25 / 50 / 75 / 100

2

100

97.8 (343.9)

90 (40.9)50 (22.7) 74 (33.6) 80 (36.4) 80 (36.4)

4515 (2048)2658 (1206) 3555 (1613) 3971 (1801) 4140 (1878) 4311 (1955)2771 (1257) 3696 (1676) 4128 (1872) 4320 (1960)

65.5 (1664)63.4 (1609) 65.5 (1664) 65.5 (1664) 65.5 (1664)

149.4 (3795)32.8 (832) 35.0 (889) 35.0 (889) 35.0 (889) 35.0 (889)

136.0 (3455) 145.5 (3695) 149.6 (3799) 149.4 (3795)

FieldField Field Field Field

3 (76)5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9)2.5 (65) 3 (76) 3 (76) 3 (76)

653 (4500)653 (4500) 653 (4500) 653 (4500) 653 (4500) 653 (4500)653 (4500) 653 (4500) 653 (4500) 653 (4500)

8.0 (30.2)3.2 (12.0) 5.6 (21.2) 6.3 (23.8) 6.8 (25.7)

1

2 2 2 2 2

1 1 1 1

IntegralIntegral Integral Integral Integral

1/2 (12.7)

1/4 (6.4) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4)

1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)

4 (102)

5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9)

4 (102) 4 (102) 4 (102) 4 (102)

232 (1599)205.4 (93.4) 415.1 (188.7) 397.5 (180.7) 371.1 (168.7) 344.7 (156.7)232 (1599) 232 (1599) 232 (1599) 232 (1599)500 (3447) 500 (3447) 500 (3447) 500 (3447) 500 (3447)

14 (356)

120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)

10 (254) 14 (356) 14 (356) 14 (356)

12 2 2 2 21 1

22 / 50 / 72 / 100 25 / 50 / 75 / 100 22 / 50 / 72 / 100

1 1

Oil Charge, per compressor oz. (l) 110 (3.3) 145 (4.3) 145 (4.3)

2 2 2 2

60.5 (212.7) 70.2 (246.8) 78.3 (275.3) 87.1 (306.3)

60 70 80 90

25 / 50 / 75 / 10025 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 22 / 50 / 72 / 100

25 / 50 / 75 / 100

32 IM 1131




WGZ UNIT SIZEUnit capacity @ AHRI tons, (kW) (Note 1) No. Circuits

COMPRESSORS Nominal Tons 26/30 26/30 30 30 26 26 26 30 30 30 Number Per Circuit 2 2 2 2 3 3 3 3 3 3

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT Staging, 4 Stages, Circuit #1 in Lead Staging, 4 Stages, Circuit #2 in Lead

145 (4.3 ) 145 (4.3 )

213 (6.3) 213 (6.3)

CONDENSER Number


Diameter, in. (mm) Tube Length, in. (mm) Design Working Pressure., psig (kPa): Refrigerant Side Water SidePump-Out Capacity- lb. (kg) (Note 2) Water Conn In & Out, in., (mm) (4) Relief Valve, Flare in., (mm) Purge Valve, Flare in. (mm) Vent & Drain, in. (mm) NPT Liquid Subcooling

EVAPORATOR, BRAZED-PLATENumber

No. Refrigerant CircuitsWater Volume- gal (l)Design Working Pressure- PSIG, (kPa): Refrigerant Side Water Side Victaulic Conn. In & Out- in. (mm) Relief Valve, Flare- in. (mm)Vent & Drain


UNIT WEIGHTSOperating Weight- lb. (kg)Shipping Weight- lb. (kg)Cir #1 R410A Oper Charge- lb. (kg) Cir #2 R410A Oper Charge- lb. (kg)

SHELL-AND-TUBE

2 2

200

213 (6.3)

188.1 (661.4)112.9 (397.0) 126.7 (445.5) 148.2 (521.1) 169.3 (595.3)2 2 2

115 130 150 170

Oil Charge, per compressor oz. (l) 145 (4.3) 145 (4.3) 213 (6.3)213 (6.3)

1

16 (406.4)

1

2 2 2 2 2

1 1 1

500 (3447)

16 (406.4)

120 (3048) 120 (3048) 144 (3658) 144 (3658) 144 (3658)

14 (356) 14 (356) 16 (406.4)

500 (3447) 500 (3447) 500 (3447) 500 (3447)232 (1599)

344.7 (156.7) 344.7 (156.7) 572.3 (260.1) 508.9 (231.3) 508.9 (231.3)232 (1599) 232 (1599) 232 (1599) 232 (1599)

5 (127)

5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9)

4 (102) 4 (102) 5 (127) 5 (127)

1/2 (12.7)1/4 (6.4) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4) 1/4 (6.4)

1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)

1 1 1

Integral Integral Integral Integral

1

450 (3102)

29.6 (36.3) 10.8 (40.9) 57.6 (218.0) 56.9 (215.4) 56.9 (215.4)

2 2 2

150 (1034)653 (4500) 653 (4500) 450 (3102) 450 (3102)

150 (1034)3 (76) 3 (76) 8 (203) 8 (203) 8 (203)

653 (4500) 653 (4500) 150 (1034)

170.3 (4326) 170.3 (4326)

Field Field 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)5/8 (15.9) 5/8 (15.9)

7509 (3406)

37.1 (927)65.5 (1664) 65.5 (1664) 76.9 (1953) 76.9 (1953) 77.7(1974)35.0 (889) 35.0 (889) 37.1 (927)

4434 (2011) 4737 (2149) 6662 (3022) 7214 (3272)

150 (68.2) 150 (68.2) 150 (68.2)4230 (1919) 4533 (2056) 5873 (2664) 6377 (2893)

150 (68.2)100 (45.5) 100 (45.5) 150 (68.2) 150 (68.2)

6672 (3026)100 (45.5) 100 (45.5)

22 / 50 / 72 / 100 25 / 50 / 75 / 100 15/33/48/67/81/100 17/33/50/67/83/10017/33/50/67/83/10022 / 50 / 72 / 100 25 / 50 / 75 / 100 19/33/52/67/86/100 17/33/50/67/83/10017 / 33 / 50 / 67

2

Integral

1

37.1 (927)149.4 (3795) 149.4 (3795) 170.3 (4326)

IM 1131 33

Physical Data - Units Less Condenser
Table 23: Physical Data - WGZ030D - AGZ055D

Note 1: Nominal capacity based on base unit capacity without derate for refrigerant piping. See Refrigerant Piping section on page 10.Note 2: Condenser and field piping not included.



WGZ UNIT SIZETons (kW) (at 44°F LWT/125°F SDT)

No. Circuits

COMPRESSORSNominal Tons 7.5 7.5 9 9 10 10 12 12 13 13 13 15Number per Circuit 2 2 2 2 2 2 2 2 2 2 2 2

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENTStaging, Circuit #1 in Lead


EVAPORATOR, BRAZED PLATENo. Refrigerant Circuits

Water Volume- gal (l)

Design Working Pressure- PSIG, (kPa): Refrigerant Side Water Side Victaulic Conn. In & Out- in. (mm) Relief Valve, Flare- in. (mm)

Vent & Drain

UNIT DIMENSIONSLength- in. (mm)

Width- in. (mm)

Height- in. (mm)

UNIT WEIGHTSOperating Weight- lb. (kg)Shipping Weight- lb. (kg) 1714 (778)1578 (716) 1662 (754) 1669 (757) 1685 (764)

2.0 (7.6) 2.3 (8.7) 2.6 (9.8)

34.0 (864) 34.0 (864)

5/8 (15.9)2.5 (65)

653 (4500)

2.5 (65)

Field

1702 (772)

2.8 (10.6)

Oil Charge per Compressor- oz. (l) 85 (2.5) 110 (3.3) 110 (3.3)

1.6 (6.1) 1.8 (6.8)

2 22

27 / 50 / 77 / 10025 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100 25 / 50 / 75 / 100

2

60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524)

1740 (789)

Field Field

5/8 (15.9) 5/8 (15.9)5/8 (15.9)

25 / 50 / 75 / 100

2.5 (65) 2.5 (65)5/8 (15.9) 5/8 (15.9)

653 (4500)653 (4500)

34.0 (864)

1755 (796)1604 (728) 1690 (767) 1699 (771) 1719 (780)

137.0 (3480) 137.0 (3480)

60.0 (1524) 60.0 (1524)

34.0 (864) 34.0 (864)

137.0 (3480) 137.0 (3480) 137.0 (3480) 137.0 (3480)

34.0 (864)

Field Field Field

653 (4500)2.5 (65) 2.5 (65)

653 (4500) 653 (4500) 653 (4500)) 653 (4500)653 (4500) 653 (4500) 653 (4500)) 653 (4500)

2 2

25 / 50 / 75 / 10025 / 50 / 75 / 100 25 / 50 / 75 / 100

110 (3.3) 110 (3.3)

25 / 50 / 75 / 100

23 / 50 / 73 / 100

110 (3.3)

25 / 50 / 75 / 100

46.3 (162.8)

22 2

36.2 (127.3) 40.3 (141.7) 50.6 (177.9)

2

26.9 (94.6) 31.2 (109.7)

2 2

30 35 40 45 50 55

WGZ UNIT SIZE

Tons (kW) (at 44°F LWT/125°F SDT)

No. Circuits

COMPRESSORSNominal Tons 15 15 15/20 15/20 20 20 20/26 20/26 26 26Number per Circuit 2 2 2 2 2 2 2 2 2 2CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENT



110 (3.3) 110 (3.3)

145 (4.3) 145 (4.3)

EVAPORATOR, BRAZED PLATENo. Refrigerant CircuitsWater Volume- gal (l)

Design Working Pressure- PSIG, (kPa): Refrigerant Side

Water Side Victaulic Conn. In & Out- in. (mm) Relief Valve, Flare- in. (mm)Vent & Drain

UNIT DIMENSIONSLength- in. (mm)Width- in. (mm)

Height- in. (mm)

UNIT WEIGHTSOperating Weight- lb. (kg)

Shipping Weight- lb. (kg)

8.0 (30.2)

1741 (790) 2228 (1010) 2579 (1170) 2701 (1225) 2841 (1289)

2923 (1326)1786 (810) 2296 (1041) 2649 (1202)

25 / 50 / 75 / 100

Oil Charge per Compressor- oz. (l) 110 (3.3) 145 (4.3) 145 (4.3) 145 (4.3) 145 (4.3)

25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100

2778 (1260)

144.0 (3658)34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864)

137.0 (3480) 144.0 (3658) 144.0 (3658) 144.0 (3658)

653 (4500)653 (4500) 653 (4500) 653 (4500) 653 (4500)

23.2 (12.0) 5.6 (21.2) 6.3 (23.8) 6.8 (25.7)

2 2 2 2

22 / 50 / 72 / 100

25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100 22 / 50 / 72 / 100 25 / 50 / 75 / 100

88.7 (311.9)

2 2 2 2 2

55.0 (193.4) 62.5 (219.8) 70.7 (248.6)

60 70 80 90 100

Field Field

653 (4500)

Field Field Field

60.0 (1524) 60.0 (1524) 60.0 (1524) 60.0 (1524)60.0 (1524)

3 (76)5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9)2.5 (63) 3 (76) 3 (76) 3 (76)

5/8 (15.9)

653 (4500) 653 (4500) 653 (4500) 653 (4500)

79.3 (278.8)

34 IM 1131




WGZ UNIT SIZETons (kW) (at 44°F LWT/125°F SDT)No. Circuits

COMPRESSORSNominal Tons 26/30 26/30 30 30 26 26 26 30 30 30Number per Circuit 2 2 2 2 3 3 3 3 3 3

CAPACITY REDUCTION STEPS - PERCENT OF COMPRESSOR DISPLACEMENTStaging, Circuit #1 in LeadStaging, Circuit #2 in Lead

145 (4.3 ) 145 (4.3 )

213 (6.3) 213 (6.3)

EVAPORATOR, BRAZED PLATE SHELL-AND-TUBE


Water Volume- gal (l)

Design Working Pressure- PSIG, (kPa): Refrigerant Side Water Side Victaulic Conn. In & Out- in. (mm) Relief Valve, Flare- in. (mm)Vent & Drain


UNIT WEIGHTSOperating Weight- lb. (kg)

Shipping Weight- lb. (kg)

56.9 (215.4)

75.0 (1905)60.0 (1524) 60.0 (1524) 75.0 (1905) 75.0 (1905)

154.0 (3912)34.0 (864)

144.0 (3658)

4640 (2105)

5134 (2334)2878 (1305) 3196 (1450) 4571 (2073) 4841 (2196)

2792 (1266) 3094 (1403) 4071 (1847) 4347 (1972)

144.0 (3658) 154.0 (3912) 154.0 (3912)34.0 (864) 34.0 (864) 34.0 (864) 34.0 (864)

1/2 (12.7)Field Field 1/2 (12.7) 1/2 (12.7)

8 (203)5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9)

3 (76) 3 (76) 8 (203) 8 (203)

450 (3102)653 (4500) 653 (4500) 150 (1034) 150 (1034) 150 (1034)653 (4500) 653 (4500) 450 (3102) 450 (3102)

2

8.5 (32.1) 10.5 (39.7) 57.6 (218.0) 56.9 (215.4)

2 2 2 2

Oil Charge per Compressor- oz. (l) 213 (6.3) 145 (4.3) 145 (4.3)

17 / 33 / 50 / 67 / 83

174.3 (612.8)2

153.7 (540.4)2

101.9 (358.3) 115.1 (404.7)

22 / 50 / 72 / 100 25 / 50 / 75 / 100 17 / 33 / 50 / 67 / 83 22 / 50 / 72 / 100 25 / 50 / 75 / 100 17 / 33 / 50 / 67 / 83

213 (6.3) 213 (6.3)

17 / 33 / 50 / 67 / 83 15 / 33 / 48 / 67 / 81 19 / 33 / 52 / 67 / 86

133.1 (468.0)2 2 2

115 130 150 200170

IM 1131 35

Start-Up and Shutdown
Start-Up and ShutdownComplete operating instructions are contained in the current version of Operating & Maintenance Manual OM 1130 found on www,daikinmcquay.com .

Pre Start-up1 The chilled-water system should be flushed and cleaned.

Proper water treatment is required to prevent corrosion and organic growth.

2 With main disconnect open, check all electrical connections in control panel and starter to be sure they are tight and provide good electrical contact. Although connections are tightened at the factory, they can loosen enough in shipment to cause a malfunction.

3 Check and inspect all water piping. Make sure flow direction is correct and piping is made to correct connection on evaporator and condenser.

4 Open all water flow valves to the condenser and evaporator.

5 Flush the cooling tower and system piping to be sure the system is clean. Start evaporator pump and manually start condenser pump and cooling tower. Check all piping for leaks. Vent the air from the evaporator and condenser water circuit, as well as from the entire water system. The cooler circuit should contain clean, treated, non-corrosive water.

6 Check to see that the evaporator water thermostat sensor is securely installed.

7 Making sure control stop switch S1 is open (off) and pumpdown switches PS1 and PS2 are on "manual pumpdown," place the main power and control disconnect switches to "on." This will energize the crankcase heaters. Wait a minimum of 12 hours before starting the unit.

8 Check compressor oil level. Prior to start-up, the oil level should cover at least one-third of the oil sight glass located in the equalizing line between the compressors or on the compressor.

9 Check water pressure drop across evaporator and condenser, and see that water flow is correct (beginning on page 17) per the design flow rates.

10 Check the actual line voltage to the unit to make sure it is the same as called for on the compressor nameplate, within + 10%, and that phase voltage unbalance does not exceed 3%. Verify that adequate power supply and capacity is available to handle load.

11 Make sure all wiring and fuses are of the proper size. Also make sure that all interlock wiring is completed per Daikin McQuay diagrams.

12 Verify that all mechanical and electrical inspections by code authorities have been completed.

13 Make sure all auxiliary load and control equipment is operative and that an adequate cooling load is available for initial start-up.

Start-up1 Open the compressor discharge shutoff valves until

backseated. Always replace valve seal caps.

2 Open the two manual liquid line shutoff valves.

3 Check to see that the unit circuit breakers are in the "off" position.

4 Check to see that the pumpdown switches, PS1 and PS2, are in the "manual pumpdown" position and the control system switch S1 is in the "off" position.

5 Put the main power and control circuit disconnects to the "on" position.

6 Verify crankcase heaters have operated for at least 12 hours prior to start-up. Crankcase should be warm to the touch.

7 Check that the MicroTech II controller is set to the desired chilled water temperature.

8 Start the system auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch and water pumps.

9 Check resets of all equipment protection controls.

10 Switch on the unit circuit breakers.

11 Set pumpdown switches PS1 and PS2 to "auto" for restart and normal operation.

12 Start the system by setting the system switch S1 to on.

13 After running the unit for a short time, check the oil level in each compressor crankcase, rotation of condenser fans (if any), and check for flashing in the refrigerant sight glass.

14 After system performance has stabilized, it is necessary that the "Compressorized Equipment Warranty Form" (Form No. 206036A) be completed to establish commencement of the warranty period. Be sure to list the pressure drop across both vessels. This form is shipped with the unit and after completion should be returned to the McQuay Service through your sales representative.

Weekend or Temporary Shutdown

Move pumpdown switches PS1 and PS2 to the "manual pumpdown" position. After the compressors have pumped down, turn off the chilled water pump. Note: With the unit in this condition, it will not restart until these switches are turned back on. The unit has one-time pumpdown. It is important that the compressors pump down before the water flow to the unit is interrupted to avoid freeze-up in the evaporator.

Leave S1 on and power to the unit so that the crankcase heaters will remain energized.

36 IM 1131


Start-up after Temporary Shutdown

1 Start the water pumps.

2 With the control system switch S1 in the "on" position, move the pumpdown switches PS1 and PS2 to the "auto pumpdown" position.

3 Observe the unit operation for a short time, noting unusual sounds or possible cycling of compressors.

4 Check compressor crankcase heaters.

Extended Shutdown

1 Close the manual liquid line shutoff valves.

2 After the compressors have pumped down, turn off the water pumps.

3 Turn off all power to the unit.

4 Move the control service switch S1 to the "off" position.

5 Close the discharge shutoff valves on the compressor(s) and the liquid outlet valves at the condenser.

6 Tag all opened disconnect switches to warn against start-up before opening the compressor suction and discharge valves.

7 Drain all water from the unit evaporator, condenser, and chilled water piping if the unit is to be shut down during the winter and exposed to below freezing temperatures. Do not leave the vessels or piping open to the atmosphere over the shutdown period.

Start-up after Extended Shutdown

1 Inspect all equipment to see that it is in satisfactory operating condition.

2 Remove all debris that has collected on the surface of the condenser coils (remote condenser models) or check the cooling tower, if present.

3 Open the compressor discharge valves until backseated. Always replace valve seal caps.

4 Open the manual liquid line shutoff valves.

5 Check circuit breakers. They must be in the "off" position.

6 Check to see that the pumpdown switches PS1 and PS2 are in the "manual shutdown" position and the control system switch S1 is in the "off" position.

7 Put the main power and control circuit disconnects to the "on" position.

8 Allow the crankcase heaters to operate for at least 12 hours prior to start-up.

9 Start the chilled water pump and purge the water piping as well as the evaporator in the unit.

10 Start the system auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch.

11 Check that the MicroTech II controller is set to the desired chilled water temperature.

12 Check resets of all equipment protection controls.

13 Switch the unit circuit breakers to "on."

14 Start the system by setting the system switch S1 to "on."

15 Set pumpdown switches PS1 and PS2 to the "auto pumpdown" position for restart and normal operation.

16 After running the unit for a short time, check the oil level in the compressor oil sight glass or in the compressor's equalizing lines for flashing indicating possible refrigerant in the oil (see System Maintenance section beginning on page 38).

CAUTION

Most relays and terminals in the control center are powered when S1 is closed and the control circuit disconnect is on. Therefore, do not close S1 until ready for start-up or serious equipment damage can

occur.

IM 1131 37

System Maintenance
System Maintenance
System Maintenance

To provide smooth operation at peak capacity and to avoid damage to package components, a program of periodic inspections should be set up and followed. The following items are intended as a guide to be used during inspection and must be combined with sound refrigeration and electrical practices to provide trouble-free performance.

The liquid line sight glass/moisture indicator on all circuits must be checked to be sure that the glass is full and clear and that the moisture indicator indicates a dry condition. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant charge, the filter-drier element must be changed.

Water supplies in some areas can tend to foul the water-cooled condenser to the point where cleaning is necessary. The fouled condenser will be indicated by an abnormally high condenser approach temperature (saturated discharge temperature minus leaving condenser water temperature) and can result in nuisance trip-outs. To clean the condenser, mechanical cleaning or a chemical descaling solution should be used according to the manufacturer's directions.

Systems with remote air-cooled condensers require periodic cleaning of the finned surface of the condenser coil.

Cleaning can be accomplished by using a cold water spray, brushing, vacuuming, or high-pressure air. No tools should be used that could damage the coil tubes or fins.

The compressor oil level must be checked periodically to be sure that the level is at the center of the oil sightglass located in the compressor's equalizing line or on the compressor itself. Low oil level can cause inadequate lubrication and if oil must be added, use oils referred to in the following Compressor Lubrication section.

A pressure tap has been provided on the liquid line downstream of the filter-drier and solenoid valve but before the expansion valve. An accurate subcooled liquid pressure and temperature can be taken here. The pressure read here could also provide an indication of excessive pressure drop through the filter-drier and solenoid valve due to a clogging filter-drier. Note: A normal pressure drop through the solenoid valve is approximately 3 psig (20.7 kPa) at full load conditions.

Electrical Terminals

All power electrical terminals should be re-tightened every six months, as they tend to loosen due to normal heating and cooling of the wire.

Compressor Lubrication

The oil level should be watched carefully upon initial start-up and regularly thereafter.

All tandem and triple compressors on WGZ units come equipped with oil equalization lines connecting the crankcase of each set of compressors in each refrigerant circuit. This allows the oil to move from one compressor crankcase to the other during normal operation, and balance between the two when the compressors are off. The oil sight glass is located in the equalization line on one circuit of the WGZ 070 and both circuits of WGZ 080 through WGZ 100. All other models have the oil sight glass in the compressor body. In either case, the oil level should be 1/4 to 1/3 of the glass.

The units are factory-charged with lubricant and one of the following lubricants must be used if lubricant is to be added to the system:

• Copeland Ultra 22 CC

• Mobil EAL Arctic 22 CC

• ICI EMKARATE RL RL 32CF

Since POEs are very hygroscopic, they will quickly absorb moisture if exposed to air. Pump the lubricant into the unit through a closed transfer system. Avoid overcharging the unit.

Oil can be added to the Copeland compressor through the oil fill hole in the crankcase. Special equipment is required to add oil and the work should be done by qualified refrigeration technicians with the proper training and equipment.CAUTION

Warranty may be affected if wiring is not in accordance with specifications. A blown fuse or tripped protector indicates a short ground or overload. Before replacing fuse or restarting compressor, the trouble must be found and corrected. It is important to have a qualified control panel electrician service this panel. Unqualified tampering with the controls can cause serious damage to equipment and void the warranty. If motor or compressor damage is suspected, do not restart until qualified service personnel have checked the unit.

DANGER

The panel is always energized to ground even when the system switch is off. To de-energize the complete panel including crankcase heaters,

pull the main unit disconnect. Failure to do so can result in severe personal injury or death.

WARNING

To avoid injury from electric shock hazard, turn off all power and perform lockout and tag-out of source before continuing with the

following service. Note that the unit might be powered from multiple sources.

WARNINGPOE lubricants must be handled carefully and the proper protective equipment (gloves, eye protection, etc.) must be used when handling POE lubricant. POE must not come into contact with any surface or material that might be harmed by POE, including certain polymers (e.g. PVC/CPVC and polycarbonate piping).

!

38 IM 1131

System Maintenance

Sightglass and Moisture Indicator

The refrigerant sight glasses should be observed periodically. A monthly observation should be adequate. A clear glass of liquid indicates that there is adequate refrigerant charge in the system to provide proper feed through the expansion valve. The sight glass should be clear when:• Ambient temperature is above 75°F (23°C)• Both compressors on a circuit are running• All fans on a circuit are running

Bubbling refrigerant in the sight glass may occur at other conditions and may indicate that the system is short of refrigerant charge. Refrigerant gas flashing in the sight glass could also indicate an excessive pressure drop in the line, possibly due to a clogged filter-drier or a restriction elsewhere in the system. An element inside the sight glass indicates what moisture condition corresponds to a given element color. If the sight glass does not indicate a dry condition after about 12 hours of operation, the unit should be pumped down and the filter-driers changed.

If the system is suspected of being short of refrigerant, a qualified service technician with EPA certification should be contacted to thoroughly check out the unit and add refrigerant if necessary.

Crankcase Heaters

The compressors are equipped with crankcase heaters. The function of the heater is to keep the temperature in the crankcase high enough to prevent refrigerant from migrating to the crankcase and condensing in the oil during off-cycle. When a system is to be started up initially, the power to the heaters should be turned on for at least 12 hours before the compressors are started. The crankcase should be up to about 80°F (26.7°C) before the system is started up, to minimize lubrication problems or liquid slugging of compressor on start-up.

If the crankcase is cool (below 80°F) (26.7°C) and the oil level in the sight glass is full to top, allow more time for oil to warm before starting the compressor.

The crankcase heaters are on whenever power is supplied to the unit and the compressor is not running.

Optional Controls

Phase/Voltage Monitor (Optional)

The phase/voltage monitor is a device that provides protection against three-phase electrical motor loss due to power failure conditions, phase loss, and phase reversal. Whenever any of these conditions occur, an input relay is deactivated, disconnecting power to the thermostatic control circuit. The compressor does a rapid shutdown pump down.

The input relay remains deactivated until power line conditions return to an acceptable level. Trip and reset delays have been provided to prevent nuisance tripping due to rapid power fluctuations.

When three-phase power has been applied, the input relay should close and the "run light" should come on. If the relay does not close, perform the following tests.

1 Check the voltages between L1-L2, L1-L3, and L2-L3. These voltages should be approximately equal and within +10% of the rated three-phase line-to-line voltage.

2 If these voltages are extremely low or widely unbalanced, check the power system to determine the cause of the problem.

3 If the voltages are good, turn off the power and interchange any two of the supply power leads at the disconnect switch. This may be necessary, as the phase/voltage monitor is sensitive to phase reversal. Turn on the power. The relay should now close after the appropriate delay.

Factory settings are as follows:

• Voltage Setting: set at nameplate voltage.

• Trip Delay Time: 2 seconds

• Restart Delay Time: 60 seconds

Hot Gas Bypass (Optional)

This option allows passage of discharge gas to the evaporator, permitting operation at lower loads than available with compressor unloading. It also keeps the velocity of refrigerant gas high enough for proper oil return at light load conditions.

The pressure regulating valve is a Sporlan® SHGBE-8 and factory set to begin opening at 69 psig and can be changed by changing the pressure setting. The adjustment range is 0 to 100 psig. To raise the pressure setting, remove the cap on the bulb and turn the adjustment screw clockwise. To lower the setting, turn the screw counterclockwise. Do not force the adjustment beyond the range it is designed for, as this will damage the adjustment assembly. The regulating valve opening point can be determined by slowly reducing the system load while observing the suction pressure. When the bypass valve starts to open, the refrigerant line on the evaporator side of the valve will begin to feel warm to the touch.

CAUTION

The hot gas line can become hot enough to cause personal injury in a very short time. Avoid contact when it is operating or

during cool-down period.

IM 1131 39

Maintenance Schedule
Maintenance Schedule
Table 26: Periodic Maintenance Schedule

I. Compressor

A. Performance evaluation (log & analysis) * O

B. Motor

Meg. windings X

Ampere balance (within 10%) X

Terminal check (tight connections, porcelain clean) X

Motor cooling (check temperature) X

C. Lubrication system

Oil level O X

Oil appearance (clear color, quantity) O

Oil change if indicated by oil analysis XII. Controls A. Operating Controls Check settings and operation X B. Protective Controls Test operation of: Alarm relay X Pump interlocks X High and low pressure alarms XIII. Condenser B. Test water quality X C. Clean condenser tubes (or as required) X D. Eddycurrent test - X E. Seasonal protection XIV. Evaporator B. Test water quality X C. Clean evaporator tubes or plates (or as required) X D. Eddycurrent test - (or as required) X E. Seasonal protection XV. Expansion Valves A. Performance evaluation (superheat control) XVI. Compressor - Chiller Unit A. Performance evaluation O B. Leak test: Compressor fittings and terminal X Piping fittings X Vessel relief valves X C. Vibration Isolation Test X D. General Appearance: Paint X Insulation XVII. Starter(s) A. Examine contactors (hardware and operation) X B. Verify overload setting and trip X C. Test electrical connections XVIII. Optional Controls A. Hot gas bypass (verify operation) X

40 IM 1131

System Service
System Service
System Service

NOTE: Anyone servicing this equipment must comply with the requirements set forth by the EPA concerning refrigerant reclamation and venting.

Filter-Driers

To change the filter-drier, pump the unit down (with the compressor running) by closing the manual liquid line shutoff valve(s). The unit will start pumping down until it reaches the low-pressure cutoff setting of 58 psi.

Close the discharge valve. Remove the refrigerant in the liquid line with a recovery unit to EPA required pressure. Remove and replace the filter-drier(s). Evacuate the lines through the liquid line manual shutoff valve(s) to remove noncondensables that may have entered during filter replacement. A leak check is recommended before returning the unit to operation.

Liquid Line Solenoid Valve

The liquid line solenoid valve(s), which are responsible for automatic pumpdown during normal unit operation, do not normally require any maintenance. However, in the event of failure they can require replacement of the solenoid coil or of the entire valve assembly.

The solenoid coil can be removed from the valve body without opening the refrigerant piping by moving pumpdown switch PS1 or PS2 to the "manual" position.

The coil can then be removed from the valve body by simply removing a nut or snap-ring located at the top of the coil. The coil can then be slipped off its mounting stud for replacement. Be sure to replace the coil on its mounting stud before returning the pumpdown switch to the "auto pumpdown" position.

To replace the entire solenoid valve, follow the steps for changing a filter-drier.

Thermostatic Expansion Valve

The expansion valve is responsible for allowing the proper amount of refrigerant to enter the evaporator regardless of cooling load. It does this by maintaining a constant superheat. (Superheat is the difference between refrigerant temperature as it leaves the evaporator and the saturation temperature corresponding to the evaporator pressure). All WGZ chillers are factory set for between 8°F and 12°F (4.4°C to 6.7°C) superheat at full load.

To increase the superheat setting of the valve, remove the cap at the bottom of the valve to expose the adjustment screw.

Turn the screw clockwise (when viewed from the adjustment screw end) to increase the superheat and counterclockwise to reduce superheat. Allow time for system rebalance after each superheat adjustment.

The expansion valve, like the solenoid valve, should not normally require replacement, but if it does, the unit must be pumped down by following the steps involved when changing a filter-drier.

If the problem can be traced to the power element only, it can be unscrewed from the valve body without removing the valve, but only after pumping the unit down.

Figure 28: Thermostatic Expansion Valve

Note: Superheat will vary with compressor unloading, but should be approximately as follows: between 8°F and 12°F (4.4°C and 6.7°C) at full load; between 6°F and 10°F at part load.

Water-cooled Condenser

The condenser is of the shell-and-tube type with water flowing through the tubes and refrigerant in the shell. Integral subcoolers are incorporated on all units. All condensers are equipped with 450 psig (2790 kPa) relief valves. Normal tube cleaning procedures can be followed.

Evaporator

The evaporators are sealed, brazed-stainless steel plate unit. or DX shell-and-tube. Normally no service work is required on the evaporator.

DANGER

Service on this equipment is to be performed only by qualified refrigeration personnel. Causes for repeated tripping of equipment

protection controls must be investigated and corrected. Disconnect all power before doing any service inside the unit or serious personal

injury or death can occur.

CAUTION

Adjustment of expansion valve should only be performed by a qualified service technician. Failure to do so can result in improper unit

operation.

IM 1131 41

Troubleshooting Chart
Troubleshooting Chart
Table 27: Troubleshooting Chart PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS

Main sw itch, circuit breakers open. Close sw itch

Fuse blow n.Check electrical circuits and motor w inding for shorts or grounds. Investigate for possible overloading. Replace fuse or reset breakers after fault is corrected.

Thermal overloads tripped or fuses blow n.Overloads are auto reset. Check unit closely w hen unit comes back on line.

Defective contactor or coil. Repair or replace.

System shut dow n by equipment protection devices.Determine type and cause of shutdow n and correct it before resetting protection sw itch.

No cooling required. None. Wait until unit calls for cooling.

Liquid line solenoid w ill not open. Repair or replace coil.

Motor electrical trouble. Check motor for opens, short circuit, or burnout.

Loose w iring. Check all w ire junctions. Tighten all terminal screw s.

Flooding of refrigerant into crankcase. Check superheat setting of expansion valve.

Improper piping support on suction or liquid line. Relocate, add or remove hangers.

Worn compressor. Replace.

Condenser w ater insufficient or temperature too high. Readjust temperature control or w ater regulating valve. Investigate w ays to increase w ater supply.

Fouled condenser tubes (w ater-cooled condenser). Clogged spray nozzles (evaporative condenser). Dirty tube and fin surface (air cooled condenser).

Clean.

Noncondensables in system. EPA purge the noncondensables.

System overcharge w ith refrigerant. Remove excess refrigerant.

Discharge shutoff valve partially closed. Open valve.

Condenser undersized (air-cooled). Check condenser rating tables against the operation.

High ambient conditions. Check condenser rating tables against the operation.

Faulty condenser temp. regulation. Check condenser control operation.

Insufficient refrigerant in system. Check for leaks. Repair and add charge.

Low suction pressure. See corrective steps for low suction pressure below .

Condenser too large. Check condenser rating table against the operation.

Low ambient conditions. Check condenser rating tables against the operation.

Excessive load. Reduce load or add additional equipment.

Expansion valve overfeeding. Check remote bulb. Regulate superheat.

Lack of refrigerant. Check for leaks. Repair and add charge.

Evaporator dirty. Clean chemically.

Clogged liquid line f ilter-drier. Replace cartridge(s).

Clogged suction line or compressor suction gas strainers. Clean strainers.

Expansion valve malfunctioning. Check and reset for proper superheat. Replace if necessary.

Condensing temperature too low . Check means for regulating condensing temperature.

Compressor w ill not unload. See corrective steps for failure of compressor to unload.

Insufficient w ater f low . Adjust f low .

Clogged suction oil strainer. Clean.

Excessive liquid in crankcase. Check crankcase heater. Reset expansion valve for higher superheat. Check liquid line solenoid valve operation.

Low oil level. Add oil.

Flooding of refrigerant into crankcase. Adjust thermal expansion valve.

Lack of refrigerant. Check for leaks and repair. Add refrigerant.

Velocity in risers too low (A-C only). Check riser sizes.

Oil trapped in line. Check pitch of lines and refrigerant velocities.

Low voltage during high load conditions. Check supply voltage for excessive line drop.

Defective or grounded w iring in motor or pow er circuits. Replace compressor-motor.

Loose pow er w iring. Check all connections and tighten.

High condensing temperature. See corrective steps for high discharge pressure.

Pow er line fault causing unbalanced voltage. Check Supply voltage. Notify pow er company. Do not start until fault is corrected.

High ambient temperature around the overload relay Provide ventilation to reduce heat.

Operating beyond design conditions. Add facilities so that conditions are w ithin allow able limits.

Discharge valve partially shut. Open valve.

Thermostat set too low . Reset to 42°F (6°C) or above.

Low w ater f low . Adjust f low .

Low suction pressure. See “Low Suction Pressure.”

Compressor Will Not Run

Compressor Noisy or Vibrating

High Suction Pressure

Low Suction Pressure

High Discharge Pressure

Low Discharge Pressure

Motor Overload Relays or Circuit Breakers

Open

Compressor Thermal Sw itch Open

Freeze Protection Opens

Little or No Oil Pressure

Compressor Loses Oil

42 IM 1131

Electrical Data

Electrical Data

Electrical Notes

Notes for "Electrical Data Single Point" Power:

1 If a separate 115V power supply is used for the control circuit, then the wire sizing amps is 10 amps for all unit sizes.

2 Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity in accordance with NEC. Voltage drop has not been included. It is recommended that power leads be kept short. All terminal block connections must be made with copper (type THW) wire.

3 The recommended power lead wire sizes are based on an ambient temperature of 86°F (30°C). Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook.

4 Must be electrically grounded according to national and local electrical codes.

Voltage Limitations:

1 Within 10 percent of nameplate rating

2 Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG-1, 1998 Standard. This is an important restriction that must be adhered to.

Notes for "Field Wiring Data"

1 Requires a single disconnect to supply electrical power to the unit. This power supply must either be fused or use an HACR type circuit breaker.

2 All field wiring to unit power block or optional non-fused disconnect switch must be copper.

3 All field wire size values given in table apply to 75°C rated wire per NEC.

Supplemental Overloads Option

The supplemental overloads option is used to reduce the required electrical service size and wire sizing (cost) to the water cooled version of WGZ chillers. The overloads reduce the electrical requirements for the chiller because water-cooled duty requires less power than air-cooled duty. The overload option is only available for WGZ-DW models with water-cooled condensers (not WGZ-DA models with air-cooled condensers) and having single point electrical power connections. Refer to the electrical data on pages 33, 37, and 38 for the reduced electrical requirements.

Circuit Breakers

The circuit breaker used in the High Short Circuit panel option may have a higher trip rating than the unit Maximum Overload Protection (MOP) value shown on the unit nameplate.

The circuit breaker is installed as a service disconnect switch and does not function as branch circuit protection, meaning that the protection device must be installed external to the unit per prevailing electric codes. The breaker (disconnect switch) is oversized to avoid nuisance trips at high ambient temperature conditions.

IM 1131 43

Electrical Data

Panel Short Circuit Current Ratings

Units without Supplemental Overloads

Standard Panel Short Circuit Current Rating

Optional High Short Circuit Current Rating Panel

Units with Supplemental Overloads

Standard Panel

Optional High Short Circuit Current Rating Panel

Voltage HzWGZ-D Model Size

WGZ 030-040 WGZ 045-090 WGZ 100-200208-230 60 5kA 5kA 5kA

380 60 5kA 5kA 5kA400 50 5kA 5kA 5kA460 60 5kA 5kA 5kA575 60 5kA 5kA 5kA

Voltage Hz Options, Single-Point Power Connection Only

208-230 60 100kA380 60 65kA400 50 65kA460 60 65kA575 60 Not Available

Voltage Hz WGZ-D Model Size WGZ 030-040 WGZ 045-090 WGZ 100-200

208-230 60 5kA 5kA 5kA380 60 5kA 5kA 5kA400 50 5kA 5kA 5kA460 60 5kA 5kA 5kA575 60 5kA 5kA 5kA

Voltage Hz Options, Single-Point Power Connection Only

208-230 60 100kA380 60 65kA400 50 65kA460 60 65kA575 60 Not Available

44 IM 1131

Electrical Data

Field Wiring Diagram (Packaged Units)

FIELD WIRING FOR WGZ030-200C

DWG. 330538901 REV.0D

PACKAGE/ WITH CONDENSER WITH MICROTECH CONTROLLER

TO C OMP RE SS OR (S)

A N D FAN MOTOR S

D ISC ON NEC T(BY OTHER S)

3 PH A SE

POW ER

120VA C

C ON TROL P OW ER

GND LUGU NIT MA IN

TERMIN AL BLOC K

FU SED CO N TR O L

CI RC U IT TR AN SF O RM ER

O PTI O N

120 VAC

TB1

T B1-20

C H W PU MP R ELAY (B Y OTHE R S)120 VA C 1.0 A MP MAX

D ISC ON N EC T(BY OTH ER S)

N

F IELDSUPPL IED

O PTIO N 10AFUS E

(BY OTH ERS )CON TR OLCI R CU IT

F US E2

1

N

120 VAC

14

11

NOTE: ALL FIELD WIRING TO BEINSTALLED AS NEC CLASS 1WIRING SYSTEM WITH CONDUCTORRATED 600 VOLTS

SU PP LY

GND

ALA RM BE LL R ELAY

FA CTOR Y SU PP LIED A LA R MFI ELD W IR ED

ALA RMBELL

O PT ION 10

15

C ON TROLLER

70

68

H OT GAS BYPASS #2 S OLEN OI D24 VAC 1. 0 AMP MAX.

70

67


65

63

LIQUID LIN E #2 SOLEN OI D24 VAC 1. 5 AMP MAX.

L ESSEVAPO RATO RO NLY

24 VAC

N

24 VAC

N

24 VAC

N

TB2

IC E MOD E S W ITC H

(BY OTH ER S)

51

52

42

60

40

53

43

55

49

50

A LA R M B ELLRE LAY

ALAR M BELL OP TION

BELL1 2

C OM N O

AU TO

TIM ECLOC K OFF

ON

M AN UA L

AU TO OF F

ON

M AN UA L

R EM OTE STOP

SW IT CH

(BY OTH ER S )

IF RE MOTE STOPCON TR OL IS U SE D,RE MOVE LEA D 897

FROM TER M. 40 TO 53.

897

4-20MA FOREVA P. W ATE R RE SE T

(BY OTH ER S )

+

-

4-20MA FOR

D EMA ND LI MIT(BY OTH ER S)

+

GN D

-

33

44

C H W FLOW S WI TC H-- -MA N DATOR Y–-

(BY OTH ER S )

NOR. OPEN PUMP AU X. CONTACTS (OPTION AL)

41

54

C D W FLOW S WI TC H-- -MA N DATOR Y–-

(BY OTH ER S )NOR. OPEN PUMP AU X. CONTACTS (OPTION AL)

65

62


N

24 VAC

N

N

120 VAC

120 VAC

120 VAC

120 VAC

C DW PUMP RELAY (BY OTHER S)120 VAC 1.0 AMP MA X

TOW ER FA N #1 COIL (BY OTHER S)120 VAC 1.0 AMP MA X


TB1-12

J 15-NO8

TB1-12

J 16-NO9

J16-N O10

TB3-90

TB3-91

TB3-92

79

80N

0-10 VDC77

78N

0-10 VDCCOOLI NG TOWE R BY PAS S

(BY OTH ER S)

COOLI NG TOWE R BY PAS S

(BY OTH ER S)

TB3

IM 1131 45

Electrical Data

Figure 29: Field Wiring Diagram (Units less condenser)

FIELD WIRING FOR WGZ030-200C

DWG. 330538901 REV.0D

PACKAGE/ WITH CONDENSER WITH MICROTECH CONTROLLER

TO C OMP RE SS OR (S)

A N D FAN MOTOR S

D ISC ON NEC T(BY OTHER S)

3 PH A SE

POW ER

120VA C

C ON TROL P OW ER

GND LUGU NIT MA IN

TERMIN AL BLOC K

FU SED CO N TR O L

CI RC U IT TR AN SF O RM ER

O PTI O N

120 VAC

TB1

T B1-20

C H W PU MP R ELAY (B Y OTHE R S)120 VA C 1.0 A MP MAX

D ISC ON N EC T(BY OTH ER S)

N

F IELDSUPPL IED

O PTIO N 10AFUS E

(BY OTH ERS )CON TR OLCI R CU IT

F US E2

1

N

120 VAC

14

11

NOTE: ALL FIELD WIRING TO BEINSTALLED AS NEC CLASS 1WIRING SYSTEM WITH CONDUCTORRATED 600 VOLTS

SU PP LY

GND

ALA RM BE LL R ELAY

FA CTOR Y SU PP LIED A LA R MFI ELD W IR ED

ALA RMBELL

O PT ION 10

15

C ON TROLLER

70

68


70

67


65

63


L ESSEVAPO RATO RO NLY

24 VAC

N

24 VAC

N

24 VAC

N

TB2

IC E MOD E S W ITC H

(BY OTH ER S)

51

52

42

60

40

53

43

55

49

50

A LA R M B ELLRE LAY

ALAR M BELL OP TION

BELL1 2

C OM N O

AU TO

TIM ECLOC K OFF

ON

M AN UA L

AU TO OF F

ON

M AN UA L

R EM OTE STOP

SW IT CH

(BY OTH ER S )

IF RE MOTE STOPCON TR OL IS U SE D,RE MOVE LEA D 897

FROM TER M. 40 TO 53.

897

4-20MA FOREVA P. W ATE R RE SE T

(BY OTH ER S )

+

-

4-20MA FOR

D EMA ND LI MIT(BY OTH ER S)

+

GN D

-

33

44

C H W FLOW S WI TC H-- -MA N DATOR Y–-

(BY OTH ER S )

NOR. OPEN PUMP AU X. CONTACTS (OPTION AL)

41

54

C D W FLOW S WI TC H-- -MA N DATOR Y–-

(BY OTH ER S )NOR. OPEN PUMP AU X. CONTACTS (OPTION AL)

65

62


N

24 VAC

N

N

120 VAC

120 VAC

120 VAC

120 VAC

C DW PUMP RELAY (BY OTHER S)120 VAC 1.0 AMP MA X



TB1-12

J 15-NO8

TB1-12

J 16-NO9

J16-N O10

TB3-90

TB3-91

TB3-92

79

80N

0-10 VDC77

78N

0-10 VDCCOOLI NG TOWE R BY PAS S

(BY OTH ER S)

COOLI NG TOWE R BY PAS S

(BY OTH ER S)

TB3

46 IM 1131

Electrical Data

Table 28: Compressor Amp Draw (with and without optional external overloads)

#1 #3 #5 #2 #4 #6 #1 #3 #5 #2 #4 #6 #1 #3 #5 #2 #4 #6

208V 29.5 29.5 -- 29.5 29.5 -- 22.4 22.4 -- 22.4 22.4 -- 195 195 -- 195 195 --

230V 29.5 29.5 -- 29.5 29.5 -- 20 20 -- 20 20 -- 195 195 -- 195 195 --

380V 16.7 16.7 -- 16.7 16.7 -- 13.6 13.6 -- 13.6 13.6 -- 123 123 -- 123 123 --

400-460V 14.7 14.7 -- 14.7 14.7 -- 12 12 -- 12 12 -- 95/95 95/95 -- 95/95 95/95 --

575V 12.2 12.2 -- 12.2 12.2 -- N/A N/A -- N/A N/A -- 80 80 -- 80 80 --

208V 30.1 30.1 -- 30.1 30.1 -- 25 25 -- 25 25 -- 225 225 -- 225 225 --

230V 30.1 30.1 -- 30.1 30.1 -- 23.2 23.2 -- 23.2 23.2 -- 225 225 -- 225 225 --

380V 19.2 19.2 -- 19.2 19.2 -- 13.8 13.8 -- 13.8 13.8 -- 140 140 -- 140 140 --

400-460V 16.7 16.7 -- 16.7 16.7 -- 12 12 -- 12 12 -- 114/111 114/111 -- 114/111 114/111 --

575V 12.2 12.2 -- 12.2 12.2 -- N/A N/A -- N/A N/A -- 80 80 -- 80 80 --

208V 33.3 33.3 -- 33.3 33.3 -- 28.6 28.6 -- 28.6 28.6 -- 239 239 -- 239 239 --

230V 33.3 33.3 -- 33.3 33.3 -- 25.6 25.6 -- 25.6 25.6 -- 239 239 -- 239 239 --

380V 23.7 23.7 -- 23.7 23.7 -- 16.9 16.9 -- 16.9 16.9 -- 145 145 -- 145 145 --

400-460V 17.9 17.9 -- 17.9 17.9 -- 12.8 12.8 -- 12.8 12.8 -- 125/118 125/118 -- 125/118 125/118 --

575V 12.8 12.8 -- 12.8 12.8 -- N/A N/A -- N/A N/A -- 80 80 -- 80 80 --

208V 48.1 48.1 -- 48.1 48.1 -- 30.5 30.5 -- 30.5 30.5 -- 245 245 -- 245 245 --

230V 48.1 48.1 -- 48.1 48.1 -- 28 28 -- 28 28 -- 245 245 -- 245 245 --

380V 23.7 23.7 -- 23.7 23.7 -- 18.3 18.3 -- 18.3 18.3 -- 145 145 -- 145 145 --

400-460V 18.6 18.6 -- 18.6 18.6 -- 14.4 14.4 -- 14.4 14.4 -- 125/118 125/118 -- 125/118 125/118 --

575V 14.7 14.7 -- 14.7 14.7 -- 12 12 -- 12 12 -- 100 100 -- 100 100 --

208V 51.3 51.3 -- 51.3 51.3 -- 36 36 -- 36 36 -- 300 300 -- 300 300 --

230V 51.3 51.3 -- 51.3 51.3 -- 32.8 32.8 -- 32.8 32.8 -- 300 300 -- 300 300 --

380V 26.9 26.9 -- 26.9 26.9 -- 19.6 19.6 -- 19.6 19.6 -- 139 139 -- 139 139 --

400-460V 23.1 23.1 -- 23.1 23.1 -- 16.8 16.8 -- 16.8 16.8 -- 150/140 150/140 -- 150/140 150/140 --

575V 19.9 19.9 -- 19.9 19.9 -- 13.6 13.6 -- 13.6 13.6 -- 109 109 -- 109 109 --

208V 51.3 51.3 -- 55.8 55.8 -- 36 36 -- 44 44 -- 300 300 -- 340 340 --

230V 51.3 51.3 -- 55.8 55.8 -- 32.8 32.8 -- 40 40 -- 300 300 -- 340 340 --

380V 26.9 26.9 -- 34 34 -- 19.6 19.6 -- 25.3 25.3 -- 139 139 -- 196 196 --

400-460V 23.1 23.1 -- 26.9 26.9 -- 16.8 16.8 -- 20 20 -- 150/140 150/140 -- 173/173 173/173 --

575V 19.9 19.9 -- 23.7 23.7 -- 13.6 13.6 -- 16 16 -- 109 109 -- 132 132 --

208V 55.8 55.8 -- 55.8 55.8 -- 44 44 -- 44 44 -- 340 340 -- 340 340 --

230V 55.8 55.8 -- 55.8 55.8 -- 40 40 -- 40 40 -- 340 340 -- 340 340 --

380V 34 34 -- 34 34 -- 25.3 25.3 -- 25.3 25.3 -- 196 196 -- 196 196 --

400-460V 26.9 26.9 -- 26.9 26.9 -- 20 20 -- 20 20 -- 173/173 173/173 -- 173/173 173/173 --

575V 23.7 23.7 -- 23.7 23.7 -- 16 16 -- 16 16 -- 132 132 -- 132 132 --

208V 73.9 55.8 -- 73.9 55.8 -- 54.4 44 -- 54.4 44 -- 505 340 -- 505 340 --

230V 73.9 55.8 -- 73.9 55.8 -- 49.6 40 -- 49.6 40 -- 505 340 -- 505 340 --

380V 38.2 34 -- 38.2 34 -- 31.2 25.3 -- 31.2 25.3 -- 290 196 -- 290 196 --

400-460V 31.4 26.9 -- 31.4 26.9 -- 24.8 20 -- 24.8 20 -- 225/220 173/173 -- 225/220 173/173 --

575V 24.6 23.7 -- 24.6 23.7 -- 20 16 -- 20 16 -- 180 132 -- 180 132 --

Circuit 2Circuit 2 Circuit 1 Circuit 2 Circuit 1

Locked Rotor Amps

Unit w/o Optional External Overloads Unit with Optional External Overloads

030D

WGZ Unit Size

Volts

Rated Load Amps Per Compressor Rated Load Amps Per Compressor

Across-The-Line Starting

Circuit 1

035D

040D

045D

050D

055D

060D

070D

IM 1131 47

Electrical Data

Table 29: Compressor Amp Draw (with and without optional external overloads)

#1 #3 #5 #2 #4 #6 #1 #3 #5 #2 #4 #6 #1 #3 #5 #2 #4 #6

208V 73.9 73.9 -- 73.9 73.9 -- 54.4 54.4 -- 54.4 54.4 -- 505 505 -- 505 505 --

230V 73.9 73.9 -- 73.9 73.9 -- 49.6 49.6 -- 49.6 49.6 -- 505 505 -- 505 505 --

380V 38.2 38.2 -- 38.2 38.2 -- 31.2 31.2 -- 31.2 31.2 -- 290 290 -- 290 290 --

400-460V 31.4 31.4 -- 31.4 31.4 -- 24.8 24.8 -- 24.8 24.8 -- 225/220 225/220 -- 225/220 225/220 --

575V 24.6 24.6 -- 24.6 24.6 -- 20 20 -- 20 20 -- 180 180 -- 180 180 --

208V 85.3 73.9 -- 85.3 73.9 -- 64.8 54.4 -- 64.8 54.4 -- 605 505 -- 605 505 --

230V 85.3 73.9 -- 85.3 73.9 -- 58.4 49.6 -- 58.4 49.6 -- 605 505 -- 605 505 --

380V 51.9 38.2 -- 51.9 38.2 -- 36.7 31.2 -- 36.7 31.2 -- 353 290 -- 353 290 --

400-460V 38.8 31.4 -- 38.8 31.4 -- 29.6 24.8 -- 29.6 24.8 -- 320/315 225/220 -- 320/315 225/220 --

575V 32.1 24.6 -- 32.1 24.6 -- 23.2 20 -- 23.2 20 -- 218 180 -- 218 180 --

208V 85.3 85.3 -- 85.3 85.3 -- 64.8 64.8 -- 64.8 64.8 -- 605 605 -- 605 605 --

230V 85.3 85.3 -- 85.3 85.3 -- 58.4 58.4 -- 58.4 58.4 -- 605 605 -- 605 605 --

380V 51.9 51.9 -- 51.9 51.9 -- 36.7 36.7 -- 36.7 36.7 -- 353 353 -- 353 353 --

400-460V 38.8 38.8 -- 38.8 38.8 -- 29.6 29.6 -- 29.6 29.6 -- 320/315 320/315 -- 320/315 320/315 --

575V 32.1 32.1 -- 32.1 32.1 -- 23.2 23.2 -- 23.2 23.2 -- 218 218 -- 218 218 --

208V 109.6 85.3 -- 109.6 85.3 -- 83.2 64.8 -- 83.2 64.8 -- 599 605 -- 599 605 --

230V 109.6 85.3 -- 109.6 85.3 -- 75.2 58.4 -- 75.2 58.4 -- 599 605 -- 599 605 --

380V 69.2 51.9 -- 69.2 51.9 -- 47.7 36.7 -- 47.7 36.7 -- 358 353 -- 358 353 --

400-460V 54.5 38.8 -- 54.5 38.8 -- 37.6 29.6 -- 37.6 29.6 -- 310/310 320/315 -- 310/310 320/315 --

575V 49.4 32.1 -- 49.4 32.1 -- 30.4 23.2 -- 30.4 23.2 -- 239 218 -- 239 218 --

208V 109.6 109.6 -- 109.6 109.6 -- 83.2 83.2 -- 83.2 83.2 -- 599 599 -- 599 599 --

230V 109.6 109.6 -- 109.6 109.6 -- 75.2 75.2 -- 75.2 75.2 -- 599 599 -- 599 599 --

380V 69.2 69.2 -- 69.2 69.2 -- 47.7 47.7 -- 47.7 47.7 -- 358 358 -- 358 358 --

400-460V 54.5 54.5 -- 54.5 54.5 -- 37.6 37.6 -- 37.6 37.6 -- 310/310 310/310 -- 310/310 310/310 --

575V 49.4 49.4 -- 49.4 49.4 -- 30.4 30.4 -- 30.4 30.4 -- 239 239 -- 239 239 --

208V 85.3 85.3 85.3 85.3 85.3 85.3 64.8 64.8 64.8 64.8 64.8 64.8 605 605 605 605 605 605

230V 85.3 85.3 85.3 85.3 85.3 85.3 58.4 58.4 58.4 58.4 58.4 58.4 605 605 605 605 605 605

380V 51.9 51.9 51.9 51.9 51.9 51.9 36.7 36.7 36.7 36.7 36.7 36.7 353 353 353 353 353 353

400-460V 38.8 38.8 38.8 38.8 38.8 38.8 29.6 29.6 29.6 29.6 29.6 29.6 320/315 320/315 320/315 320/315 320/315 320/315

575V 32.1 32.1 32.1 32.1 32.1 32.1 23.2 23.2 23.2 23.2 23.2 23.2 218 218 218 218 218 218

208V 85.3 85.3 85.3 109.6 109.6 109.6 64.8 64.8 64.8 83.2 83.2 83.2 605 605 605 599 599 599

230V 85.3 85.3 85.3 109.6 109.6 109.6 58.4 58.4 58.4 75.2 75.2 75.2 605 605 605 599 599 599

380V 51.9 51.9 51.9 69.2 69.2 69.2 36.7 36.7 36.7 47.7 47.7 47.7 353 353 353 358 358 358

400-460V 38.8 38.8 38.8 54.5 54.5 54.5 29.6 29.6 29.6 37.6 37.6 37.6 320/315 320/315 320/315 310/310 310/310 310/310

575V 32.1 32.1 32.1 49.4 49.4 49.4 23.2 23.2 23.2 30.4 30.4 30.4 218 218 218 239 239 239

208V 109.6 109.6 109.6 109.6 109.6 109.6 83.2 83.2 83.2 83.2 83.2 83.2 599 599 599 599 599 599

230V 109.6 109.6 109.6 109.6 109.6 109.6 75.2 75.2 75.2 75.2 75.2 75.2 599 599 599 599 599 599

380V 69.2 69.2 69.2 69.2 69.2 69.2 47.7 47.7 47.7 47.7 47.7 47.7 358 358 358 358 358 358

400-460V 54.5 54.5 54.5 54.5 54.5 54.5 37.6 37.6 37.6 37.6 37.6 37.6 310/310 310/310 310/310 310/310 310/310 310/310

575V 49.4 49.4 49.4 49.4 49.4 49.4 30.4 30.4 30.4 30.4 30.4 30.4 239 239 239 239 239 239

080D

150D

170D

200D

WGZ Unit Size

090D

100D

115D

130D

Volts

Rated Load Amps Per Compressor Rated Load Amps Per Compressor

Circuit 1 Circuit 2 Circuit 1 Circuit 2 Circuit 1 Circuit 2

Locked Rotor Amps

Unit w/o Optional External Overloads Unit with Optional External Overloads Across-The-Line Starting

48 IM 1131

Electrical Data

Table 30: Wire Sizing Amps - Single Point without optional External Overloads

Qty Wire GA Qty Size Qty Wire GA Qty Size

208V 126 3 1 AWG 1 1.25 150 208V 315 3 400 MCM 1 2.50 350230V 126 3 1 AWG 1 1.25 150 230V 315 3 400 MCM 1 2.50 350380V 71 3 4 AWG 1 1.00 80 380V 163 3 2/0 AWG 1 1.50 200

400-460V 63 3 6 AWG 1 0.75 70 400-460V 134 3 1/0 AWG 1 1.50 150575V 52 3 6 AWG 1 0.75 60 575V 105 3 2 AWG 1 1.25 125

208V 128 3 1 AWG 1 1.25 150 208V 337 6 4/0 AWG 1 3.00 400230V 128 3 1 AWG 1 1.25 150 230V 337 6 4/0 AWG 1 3.00 400380V 82 3 4 AWG 1 1.00 100 380V 190 3 3/0 AWG 1 2.00 225


208V 142 3 1/0 AWG 1 1.50 175 208V 363 6 4/0 AWG 1 3.00 400230V 142 3 1/0 AWG 1 1.50 175 230V 363 6 4/0 AWG 1 3.00 400380V 101 3 2 AWG 1 1.25 110 380V 221 3 4/0 AWG 1 2.00 250

400-460V 77 3 4 AWG 1 1.00 90 400-460V 165 3 2/0 AWG 1 1.50 200575V 55 3 6 AWG 1 0.75 60 575V 137 3 1/0 AWG 1 1.50 150

208V 205 3 4/0 AWG 1 2.00 250 208V 412 6 4/0 AWG 2 2.00 450230V 205 3 4/0 AWG 1 2.00 250 230V 412 6 4/0 AWG 2 2.00 450380V 101 3 2 AWG 1 1.25 110 380V 256 3 300 MCM 1 2.50 300


208V 218 3 4/0 AWG 1 2.00 250 208V 466 6 250 MCM 2 2.00 500230V 218 3 4/0 AWG 1 2.00 250 230V 466 6 250 MCM 2 2.00 500380V 115 3 2 AWG 1 1.25 125 380V 295 3 350 MCM 1 2.50 350

400-460V 99 3 3 AWG 1 1.00 110 400-460V 232 3 250 MCM 1 2.00 250575V 85 3 4 AWG 1 1.00 100 575V 210 3 4/0 AWG 1 2.00 250

208V 229 3 4/0 AWG 1 2.00 250 208V 534 6 300 MCM 2 2.50 600230V 229 3 4/0 AWG 1 2.00 250 230V 534 6 300 MCM 2 2.50 600380V 131 3 1/0 AWG 1 1.50 150 380V 325 3 400 MCM 1 2.50 350


208V 238 3 250 MCM 1 2.00 250 208V 613 6 350 MCM 2 2.50 700230V 238 3 250 MCM 1 2.00 250 230V 613 6 350 MCM 2 2.50 700380V 145 3 1/0 AWG 1 1.50 175 380V 381 6 250 MCM 1 3.00 400

400-460V 115 3 2 AWG 1 1.25 125 400-460V 294 3 350 MCM 1 2.50 300575V 101 3 2 AWG 1 1.25 110 575V 257 3 300 MCM 1 2.50 300

208V 274 3 300 MCM 1 2.50 300 208V 685 12 250 MCM 2 3.00 700230V 274 3 300 MCM 1 2.50 300 230V 685 12 250 MCM 2 3.00 700380V 153 3 2/0 AWG 1 1.50 175 380V 433 6 4/0 AWG 2 2.00 500

400-460V 124 3 1 AWG 1 1.25 150 400-460V 341 6 4/0 AWG 1 3.00 350575V 103 3 2 AWG 1 1.25 125 575V 309 3 350 MCM 1 2.50 350

030D

035D

040D

045D

050D

055D

060D

070D

080D

090D

100D

115D

130D

150D

170D

200D

Max Fuse Size

Model Size

Voltage MCAField Wire Field Hub. Model

SizeVoltage MCA

Max Fuse Size

Field Wire Field Hub.

IM 1131 49

Electrical Data

Table 31: Wire Sizing Amps - Single Point with optional External Overloads


208V 96 3 3 AWG 1 1.00 110 208V 232 3 250 MCM 1 2.00 250230V 85 3 3 AWG 1 1.00 100 230V 211 3 4/0 AWG 1 2.00 250380V 58 3 6 AWG 1 0.75 70 380V 133 3 1/0 AWG 1 1.50 150

400-460V 51 3 6 AWG 1 0.75 60 400-460V 106 3 2 AWG 1 1.25 125575V N/A -- -- -- -- -- 575V 85 3 3 AWG 1 1.00 100

208V 107 3 2 AWG 1 1.25 125 208V 252 3 250 MCM 1 2.00 300230V 99 3 3 AWG 1 1.00 110 230V 229 3 4/0 AWG 1 2.00 250380V 59 3 6 AWG 1 0.75 70 380V 144 3 1/0 AWG 1 1.50 175






208V 153 3 2/0 AWG 1 1.50 175 208V 354 6 4/0 AWG 1 3.00 400230V 140 3 1/0 AWG 1 1.50 150 230V 320 3 400 MCM 1 2.50 350380V 84 3 4 AWG 1 1.00 100 380V 203 3 4/0 AWG 1 2.00 250


208V 171 3 2/0 AWG 1 1.50 200 208V 405 6 250 MCM 1 3.00 450230V 156 3 2/0 AWG 1 1.50 175 230V 365 6 4/0 AWG 1 3.00 400380V 97 3 3 AWG 1 1.00 110 380V 230 3 4/0 AWG 1 2.00 250


208V 187 3 3/0 AWG 1 2.00 225 208V 465 6 250 MCM 2 2.00 500230V 170 3 2/0 AWG 1 1.50 200 230V 420 6 4/0 AWG 2 2.00 450380V 108 3 2 AWG 1 1.25 125 380V 266 3 300 MCM 1 2.50 300


208V 208 3 4/0 AWG 1 2.00 250 208V 520 6 300 MCM 2 2.50 600230V 190 3 3/0 AWG 1 2.00 225 230V 470 6 250 MCM 2 2.00 500380V 120 3 1 AWG 1 1.25 125 380V 299 3 350 MCM 1 2.50 300


Field Hub.Model Size

Voltage MCAMax Fuse

Field Wire Field Hub. Field Wire

050D

055D

060D

Max Fuse

030D

035D

040D

Model Size

Voltage MCA

070D

080D

090D

100D

115D

130D

150D

170D

200D

045D

50 IM 1131

Electrical Data

Table 32: Wire Sizing Amps - Multi-Point without optional External Overloads


208V 66 3 4 AWG 1 1.00 90 66 3 4 AWG 1 1.00 90

230V 66 3 4 AWG 1 1.00 90 66 3 4 AWG 1 1.00 90

380V 38 3 8 AWG 1 0.50 50 38 3 8 AWG 1 0.50 50

400-460V 33 3 10 AWG 1 0.50 45 33 3 10 AWG 1 0.50 45

575V 27 3 10 AWG 1 0.50 35 27 3 10 AWG 1 0.50 35

208V 68 3 4 AWG 1 1.00 90 68 3 4 AWG 1 1.00 90

230V 68 3 4 AWG 1 1.00 90 68 3 4 AWG 1 1.00 90

380V 43 3 8 AWG 1 0.50 60 43 3 8 AWG 1 0.50 60

400-460V 38 3 8 AWG 1 0.50 50 38 3 8 AWG 1 0.50 50

575V 27 3 10 AWG 1 0.50 35 27 3 10 AWG 1 0.50 35

208V 75 3 4 AWG 1 1.00 100 75 3 4 AWG 1 1.00 100

230V 75 3 4 AWG 1 1.00 100 75 3 4 AWG 1 1.00 100

380V 53 3 6 AWG 1 0.75 70 53 3 6 AWG 1 0.75 70

400-460V 40 3 8 AWG 1 0.50 50 40 3 8 AWG 1 0.50 50

575V 29 3 10 AWG 1 0.50 40 29 3 10 AWG 1 0.50 40

208V 108 3 2 AWG 1 1.25 150 108 3 2 AWG 1 1.25 150

230V 108 3 2 AWG 1 1.25 150 108 3 2 AWG 1 1.25 150

380V 53 3 6 AWG 1 0.75 70 53 3 6 AWG 1 0.75 70

400-460V 42 3 8 AWG 1 0.50 60 42 3 8 AWG 1 0.50 60

575V 33 3 10 AWG 1 0.50 45 33 3 10 AWG 1 0.50 45

208V 115 3 2 AWG 1 1.25 150 115 3 2 AWG 1 1.25 150

230V 115 3 2 AWG 1 1.25 150 115 3 2 AWG 1 1.25 150

380V 61 3 6 AWG 1 0.75 80 61 3 6 AWG 1 0.75 80

400-460V 52 3 6 AWG 1 0.75 70 52 3 6 AWG 1 0.75 70

575V 45 3 8 AWG 1 0.50 60 45 3 8 AWG 1 0.50 60

208V 115 3 2 AWG 1 1.25 150 126 3 1 AWG 1 1.25 175

230V 115 3 2 AWG 1 1.25 150 126 3 1 AWG 1 1.25 175

380V 61 3 6 AWG 1 0.75 80 77 3 4 AWG 1 1.00 110

400-460V 52 3 6 AWG 1 0.75 70 61 3 6 AWG 1 0.75 80

575V 45 3 8 AWG 1 0.50 60 53 3 6 AWG 1 0.75 70

208V 126 3 1 AWG 1 1.25 175 126 3 1 AWG 1 1.25 175

230V 126 3 1 AWG 1 1.25 175 126 3 1 AWG 1 1.25 175

380V 77 3 4 AWG 1 1.00 110 77 3 4 AWG 1 1.00 110

400-460V 61 3 6 AWG 1 0.75 80 61 3 6 AWG 1 0.75 80

575V 53 3 6 AWG 1 0.75 70 53 3 6 AWG 1 0.75 70

208V 144 3 1/0 AWG 1 1.50 175 144 3 1/0 AWG 1 1.50 175

230V 144 3 1/0 AWG 1 1.50 175 144 3 1/0 AWG 1 1.50 175

380V 81 3 4 AWG 1 1.00 110 81 3 4 AWG 1 1.00 110

400-460V 65 3 6 AWG 1 0.75 90 65 3 6 AWG 1 0.75 90

575V 54 3 6 AWG 1 0.75 70 54 3 6 AWG 1 0.75 70

208V 166 3 2/0 AWG 1 1.50 225 166 3 2/0 AWG 1 1.50 225

230V 166 3 2/0 AWG 1 1.50 225 166 3 2/0 AWG 1 1.50 225

380V 86 3 3 AWG 1 1.00 110 86 3 3 AWG 1 1.00 110

400-460V 71 3 4 AWG 1 1.00 100 71 3 4 AWG 1 1.00 100

575V 55 3 6 AWG 1 0.75 80 55 3 6 AWG 1 0.75 80

208V 178 3 3/0 AWG 1 2.00 250 178 3 3/0 AWG 1 2.00 250

230V 178 3 3/0 AWG 1 2.00 250 178 3 3/0 AWG 1 2.00 250

380V 100 3 3 AWG 1 1.00 125 100 3 3 AWG 1 1.00 125

400-460V 78 3 4 AWG 1 1.00 100 78 3 4 AWG 1 1.00 100

575V 63 3 6 AWG 1 0.75 80 63 3 6 AWG 1 0.75 80

060D

070D

080D

090D

Cir. 2MCA

Max Fuse Size

030D

035D

Field Wire Field Hub. Field Wire Field Hub.Model Size

VoltageCir. 1MCA

Max Fuse Size

050D

055D

040D

045D

IM 1131 51

Electrical Data

Table 33: Wire Sizing Amps - Multi-Point without optional External Overloads (continued)


208V 192 3 3/0 AWG 1 2.00 250 192 3 3/0 AWG 1 2.00 250

230V 192 3 3/0 AWG 1 2.00 250 192 3 3/0 AWG 1 2.00 250

380V 117 3 1 AWG 1 1.25 150 117 3 1 AWG 1 1.25 150

400-460V 87 3 3 AWG 1 1.00 125 87 3 3 AWG 1 1.00 125

575V 72 3 4 AWG 1 1.00 100 72 3 4 AWG 1 1.00 100

208V 216 3 4/0 AWG 1 2.00 300 216 3 4/0 AWG 1 2.00 300

230V 216 3 4/0 AWG 1 2.00 300 216 3 4/0 AWG 1 2.00 300

380V 134 3 1/0 AWG 1 1.50 175 134 3 1/0 AWG 1 1.50 175

400-460V 103 3 2 AWG 1 1.25 125 103 3 2 AWG 1 1.25 125

575V 90 3 3 AWG 1 1.00 110 90 3 3 AWG 1 1.00 110

208V 247 3 250 MCM 1 2.00 350 247 3 250 MCM 1 2.00 350

230V 247 3 250 MCM 1 2.00 350 247 3 250 MCM 1 2.00 350

380V 156 3 2/0 AWG 1 1.50 225 156 3 2/0 AWG 1 1.50 225

400-460V 123 3 1 AWG 1 1.25 175 123 3 1 AWG 1 1.25 175

575V 111 3 2 AWG 1 1.25 150 111 3 2 AWG 1 1.25 150

208V 277 3 300 MCM 1 2.50 350 277 3 300 MCM 1 2.50 350

230V 277 3 300 MCM 1 2.50 350 277 3 300 MCM 1 2.50 350

380V 169 3 2/0 AWG 1 1.50 200 169 3 2/0 AWG 1 1.50 200

400-460V 126 3 1 AWG 1 1.25 150 126 3 1 AWG 1 1.25 150

575V 104 3 2 AWG 1 1.25 125 104 3 2 AWG 1 1.25 125

208V 277 3 300 MCM 1 2.50 350 356 6 4/0 AWG 1 3.00 450

230V 277 3 300 MCM 1 2.50 350 356 6 4/0 AWG 1 3.00 450

380V 169 3 2/0 AWG 1 1.50 200 225 3 4/0 AWG 1 2.00 250

400-460V 126 3 1 AWG 1 1.25 150 177 3 3/0 AWG 1 2.00 225

575V 104 3 2 AWG 1 1.25 125 161 3 2/0 AWG 1 1.50 200

208V 356 6 4/0 AWG 1 3.00 450 356 6 4/0 AWG 1 3.00 450

230V 356 6 4/0 AWG 1 3.00 450 356 6 4/0 AWG 1 3.00 450

380V 225 3 4/0 AWG 1 2.00 250 225 3 4/0 AWG 1 2.00 250

400-460V 177 3 3/0 AWG 1 2.00 225 177 3 3/0 AWG 1 2.00 225

575V 161 3 2/0 AWG 1 1.50 200 161 3 2/0 AWG 1 1.50 200


100D

115D

Model Size

130D

150D

170D

200D

Max Fuse Size

VoltageCir. 1MCA

Max Fuse Size

Cir. 2MCA


52 IM 1131

Electrical Data

Table 34: Wire Sizing Amps - Multi-Point with optional External Overloads


208V 50 3 8 AWG 1 0.50 70 50 3 8 AWG 1 0.50 70

230V 45 3 8 AWG 1 0.50 60 45 3 8 AWG 1 0.50 60

380V 31 3 10 AWG 1 0.50 40 31 3 10 AWG 1 0.50 40

400-460V 27 3 10 AWG 1 0.50 35 27 3 10 AWG 1 0.50 35

575V N/A -- -- -- -- -- N/A -- -- -- -- --

208V 56 3 6 AWG 1 0.75 80 56 3 6 AWG 1 0.75 80

230V 52 3 6 AWG 1 0.75 70 52 3 6 AWG 1 0.75 70

380V 31 3 10 AWG 1 0.50 45 31 3 10 AWG 1 0.50 45

400-460V 27 3 10 AWG 1 0.50 35 27 3 10 AWG 1 0.50 35

575V N/A -- -- -- -- -- N/A -- -- -- -- --

208V 64 3 6 AWG 1 0.75 90 64 3 6 AWG 1 0.75 90

230V 58 3 6 AWG 1 0.75 80 58 3 6 AWG 1 0.75 80

380V 38 3 8 AWG 1 0.50 50 38 3 8 AWG 1 0.50 50

400-460V 29 3 10 AWG 1 0.50 40 29 3 10 AWG 1 0.50 40

575V N/A -- -- -- -- -- N/A -- -- -- -- --

208V 69 3 4 AWG 1 1.00 90 69 3 4 AWG 1 1.00 90

230V 63 3 6 AWG 1 0.75 90 63 3 6 AWG 1 0.75 90

380V 41 3 8 AWG 1 0.50 50 41 3 8 AWG 1 0.50 50

400-460V 32 3 10 AWG 1 0.50 45 32 3 10 AWG 1 0.50 45

575V 27 3 10 AWG 1 0.50 35 27 3 10 AWG 1 0.50 35

208V 81 3 4 AWG 1 1.00 110 81 3 4 AWG 1 1.00 110

230V 74 3 4 AWG 1 1.00 100 74 3 4 AWG 1 1.00 100

380V 44 3 8 AWG 1 0.50 60 44 3 8 AWG 1 0.50 60

400-460V 38 3 8 AWG 1 0.50 50 38 3 8 AWG 1 0.50 50

575V 31 3 10 AWG 1 0.50 40 31 3 10 AWG 1 0.50 40

208V 81 3 4 AWG 1 1.00 110 99 3 3 AWG 1 1.00 125

230V 74 3 4 AWG 1 1.00 100 90 3 3 AWG 1 1.00 125

380V 44 3 8 AWG 1 0.50 60 57 3 6 AWG 1 0.75 80

400-460V 38 3 8 AWG 1 0.50 50 45 3 8 AWG 1 0.50 60

575V 31 3 10 AWG 1 0.50 40 36 3 8 AWG 1 0.50 50

208V 99 3 3 AWG 1 1.00 125 99 3 3 AWG 1 1.00 125

230V 90 3 3 AWG 1 1.00 125 90 3 3 AWG 1 1.00 125

380V 57 3 6 AWG 1 0.75 80 57 3 6 AWG 1 0.75 80

400-460V 45 3 8 AWG 1 0.50 60 45 3 8 AWG 1 0.50 60

575V 36 3 8 AWG 1 0.50 50 36 3 8 AWG 1 0.50 50

208V 109 3 2 AWG 1 1.25 150 109 3 2 AWG 1 1.25 150

230V 100 3 3 AWG 1 1.00 125 100 3 3 AWG 1 1.00 125

380V 63 3 6 AWG 1 0.75 80 63 3 6 AWG 1 0.75 80

400-460V 50 3 8 AWG 1 0.50 70 50 3 8 AWG 1 0.50 70

575V 40 3 8 AWG 1 0.50 50 40 3 8 AWG 1 0.50 50

208V 122 3 1 AWG 1 1.25 175 122 3 1 AWG 1 1.25 175

230V 112 3 2 AWG 1 1.25 150 112 3 2 AWG 1 1.25 150

380V 70 3 4 AWG 1 1.00 100 70 3 4 AWG 1 1.00 100

400-460V 56 3 6 AWG 1 0.75 80 56 3 6 AWG 1 0.75 80

575V 45 3 8 AWG 1 0.50 60 45 3 8 AWG 1 0.50 60

208V 133 3 1/0 AWG 1 1.50 175 133 3 1/0 AWG 1 1.50 175

230V 120 3 1 AWG 1 1.25 150 120 3 1 AWG 1 1.25 150

380V 76 3 4 AWG 1 1.00 100 76 3 4 AWG 1 1.00 100

400-460V 61 3 6 AWG 1 0.75 80 61 3 6 AWG 1 0.75 80

575V 48 3 8 AWG 1 0.50 60 48 3 8 AWG 1 0.50 60

Field Wire

030D

035D

040D

Field Wire Field Hub. Max Fuse Size

Cir. 2MCA

090D

Field Hub.Model Size

VoltageCir. 1MCA

060D

070D

080D

Max Fuse Size

045D

050D

055D

IM 1131 53

Electrical Data

Table 35: Wire Sizing Amps - Multi-Point with optional External Overloads (continued)


208V 146 3 1/0 AWG 1 1.50 200 146 3 1/0 AWG 1 1.50 200

230V 131 3 1/0 AWG 1 1.50 175 131 3 1/0 AWG 1 1.50 175

380V 83 3 4 AWG 1 1.00 110 83 3 4 AWG 1 1.00 110

400-460V 67 3 4 AWG 1 1.00 90 67 3 4 AWG 1 1.00 90

575V 52 3 6 AWG 1 0.75 70 52 3 6 AWG 1 0.75 70

208V 164 3 2/0 AWG 1 1.50 225 164 3 2/0 AWG 1 1.50 225

230V 148 3 1/0 AWG 1 1.50 200 148 3 1/0 AWG 1 1.50 200

380V 94 3 3 AWG 1 1.00 125 94 3 3 AWG 1 1.00 125

400-460V 75 3 4 AWG 1 1.00 100 75 3 4 AWG 1 1.00 100

575V 59 3 6 AWG 1 0.75 80 59 3 6 AWG 1 0.75 80

208V 187 3 3/0 AWG 1 2.00 250 187 3 3/0 AWG 1 2.00 250

230V 169 3 2/0 AWG 1 1.50 225 169 3 2/0 AWG 1 1.50 225

380V 107 3 2 AWG 1 1.25 150 107 3 2 AWG 1 1.25 150

400-460V 85 3 4 AWG 1 1.00 110 85 3 4 AWG 1 1.00 110

575V 68 3 4 AWG 1 1.00 90 68 3 4 AWG 1 1.00 90

208V 211 3 4/0 AWG 1 2.00 250 211 3 4/0 AWG 1 2.00 250

230V 190 3 3/0 AWG 1 2.00 225 190 3 3/0 AWG 1 2.00 225

380V 119 3 1 AWG 1 1.25 150 119 3 1 AWG 1 1.25 150

400-460V 96 3 3 AWG 1 1.00 125 96 3 3 AWG 1 1.00 125

575V 75 3 4 AWG 1 1.00 90 75 3 4 AWG 1 1.00 90

208V 211 3 4/0 AWG 1 2.00 250 270 3 300 MCM 1 2.50 350

230V 190 3 3/0 AWG 1 2.00 225 244 3 250 MCM 1 2.00 300

380V 119 3 1 AWG 1 1.25 150 155 3 2/0 AWG 1 1.50 200

400-460V 96 3 3 AWG 1 1.00 125 122 3 1 AWG 1 1.25 150

575V 75 3 4 AWG 1 1.00 90 99 3 3 AWG 1 1.00 125

208V 270 3 300 MCM 1 2.50 350 270 3 300 MCM 1 2.50 350

230V 244 3 250 MCM 1 2.00 300 244 3 250 MCM 1 2.00 300

380V 155 3 2/0 AWG 1 1.50 200 155 3 2/0 AWG 1 1.50 200

400-460V 122 3 1 AWG 1 1.25 150 122 3 1 AWG 1 1.25 150

575V 99 3 3 AWG 1 1.00 125 99 3 3 AWG 1 1.00 125

Model Size

VoltageCir. 1MCA

100D

115D

130D

Field Wire

150D

170D

200D

Field Hub.Max Fuse Size

Field WireField Hub.Max Fuse Size

Cir. 2MCA

54 IM 1131

Electrical Data

Table 36: Connection Sizing - Single Point without optional External Overloads

Note [1]: On HSCCR Unit = 250A {(1) 350 - #6}Note [2]: Power Block and Disconnect Switch sizes are the minimum. Larger sizes may be used, however lug range must be same.

Model Voltage Model VoltageSize Size Size Lug Range Size Lug Range Size Size Size Lug Range Size Lug Range

208V 175A (1) 2/0 - #14 250A (1) 350 - #6 208V 380A (1) 500 - #4 400A (2) 500 - 3/0230V 175A (1) 2/0 - #14 250A (1) 350 - #6 230V 380A (1) 500 - #4 400A (2) 500 - 3/0380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 380V 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3

208V 175A (1) 2/0 - #14 250A (1) 350 - #6 208V 380A (1) 500 - #4 400A (2) 500 - 3/0230V 175A (1) 2/0 - #14 250A (1) 350 - #6 230V 380A (1) 500 - #4 400A (2) 500 - 3/0380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 380V 380A (1) 500 - #4 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 175A (1) 2/0 - #14 250A (1) 350 - #6


400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 175A (1) 2/0 - #14 250A (1) 350 - #6

208V 380A (1) 500 - #4 250A (1) 350 - #6 208V 760A (2) 500 - #4 600A (2) 500 - 3/0230V 380A (1) 500 - #4 250A (1) 350 - #6 230V 760A (2) 500 - #4 600A (2) 500 - 3/0380V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 380V 380A (1) 500 - #4 400A (2) 500 - 3/0

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 380A (1) 500 - #4 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 380A (1) 500 - #4 250A (1) 350 - #6


400-460V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 400-460V 380A (1) 500 - #4 400A (2) 500 - 3/0575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 380A (1) 500 - #4 250A (1) 350 - #6

208V 380A (1) 500 - #4 250A (1) 350 - #6 208V 760A (2) 500 - #4 600A (2) 500 - 3/0230V 380A (1) 500 - #4 250A (1) 350 - #6 230V 760A (2) 500 - #4 600A (2) 500 - 3/0380V 175A (1) 2/0 - #14 250A (1) 350 - #6 380V 380A (1) 500 - #4 400A (2) 500 - 3/0

400-460V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 400-460V 380A (1) 500 - #4 400A (2) 500 - 3/0575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 575V 380A (1) 500 - #4 250A (1) 350 - #6

208V 380A (1) 500 - #4 400A (2) 500 - 3/0 208V 760A (2) 500 - #4 800A (3) 500 - 3/0230V 380A (1) 500 - #4 400A (2) 500 - 3/0 230V 760A (2) 500 - #4 800A (3) 500 - 3/0380V 175A (1) 2/0 - #14 250A (1) 350 - #6 380V 760A (2) 500 - #4 600A (2) 500 - 3/0

400-460V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 400-460V 380A (1) 500 - #4 400A (2) 500 - 3/0575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 575V 380A (1) 500 - #4 400A (2) 500 - 3/0

208V 380A (1) 500 - #4 400A (2) 500 - 3/0 208V 760A (2) 500 - #4 800A (4) 500 - 250230V 380A (1) 500 - #4 400A (2) 500 - 3/0 230V 760A (2) 500 - #4 800A (4) 500 - 250380V 175A (1) 2/0 - #14 250A (1) 350 - #6 380V 760A (2) 500 - #4 600A (2) 500 - 3/0

400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6 400-460V 380A (1) 500 - #4 400A (2) 500 - 3/0575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 575V 380A (1) 500 - #4 400A (2) 500 - 3/0

130D

150D

170D

200D

050D

055D

060D

070D

030D

035D

040D

045D

Pow er Block [2] Disconnect Sw itch [2]Power Block [2] Disconnect Switch [2]

080D

090D

100D

115D

IM 1131 55

Electrical Data

Table 37: Connection Sizing - Single Point with optional External Overloads


Model Voltage Model VoltageSize Size Size Lug Range Size Lug Range Size Size Size Lug Range Size Lug Range

208V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 208V 380A (1) 500 - #4 400A (2) 500 - 3/0230V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 230V 380A (1) 500 - #4 250A (1) 350 - #6380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 380V 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3575V N/A -- N/A -- 575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

208V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 208V 380A (1) 500 - #4 400A (2) 500 - 3/0230V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 230V 380A (1) 500 - #4 250A (1) 350 - #6380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 380V 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6575V N/A -- N/A -- 575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

208V 175A (1) 2/0 - #14 250A (1) 350 - #6 208V 380A (1) 500 - #4 400A (2) 500 - 3/0230V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 230V 380A (1) 500 - #4 400A (2) 500 - 3/0380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 380V 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6575V N/A -- N/A -- 575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3


400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3


400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 175A (1) 2/0 - #14 250A (1) 350 - #6

208V 380A (1) 500 - #4 250A (1) 350 - #6 208V 760A (2) 500 - #4 600A (2) 500 - 3/0230V 175A (1) 2/0 - #14 250A (1) 350 - #6 230V 380A (1) 500 - #4 600A (2) 500 - 3/0380V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 380V 380A (1) 500 - #4 400A (2) 500 - 3/0

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 380A (1) 500 - #4 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 175A (1) 2/0 - #14 250A (1) 350 - #6


400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 400-460V 380A (1) 500 - #4 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 380A (1) 500 - #4 250A (1) 350 - #6

208V 380A (1) 500 - #4 250A (1) 350 - #6 208V 760A (2) 500 - #4 600A (2) 500 - 3/0230V 380A (1) 500 - #4 250A (1) 350 - #6 230V 760A (2) 500 - #4 600A (2) 500 - 3/0380V 175A (1) 2/0 - #14 250A (1) 350 - #6 380V 380A (1) 500 - #4 400A (2) 500 - 3/0

400-460V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 400-460V 380A (1) 500 - #4 400A (2) 500 - 3/0575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 575V 380A (1) 500 - #4 250A (1) 350 - #6

130D

150D

170D

200D

080D

090D

100D

115D

050D

055D

060D

070D

030D

035D

040D

045D

Power Block [2] Disconnect Switch [2]Power Block [2] Disconnect Switch [2]

56 IM 1131

Electrical Data

Table 38: Connection Sizing - Multi-Point without optional External Overloads


Model VoltageSize Size Size Lug Range Size Lug Range Size Lug Range Size Lug Range

208V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10230V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10230V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10




400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 250A (1) 350 - #6230V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 250A (1) 350 - #6380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6230V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10


400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

050D

055D

060D

070D

030D

035D

040D

045D

Cir #1 Disconnect Sw [2] Cir #1 Power Block [2] Cir #2 Power Block [2] Cir #2 Disconnect Sw [2]

IM 1131 57

Electrical Data

Table 39: Connection Sizing - Multi-Point without optional External Overloads (continued)



208V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6230V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6230V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6380V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3


400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6230V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6380V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0230V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0380V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3208V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0230V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0380V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3208V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0230V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0380V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 250A (1) 350 - #6208V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0230V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0380V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6

400-460V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6575V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6

130D

150D

170D

200D

080D

090D

100D

115D

Cir #1 Power Block [2] Cir #1 Disconnect Sw [2] Cir #2 Power Block [2] Cir #2 Disconnect Sw [2]

58 IM 1131

Electrical Data

Table 40: Connection Sizing - Multi-Point with optional External Overloads



208V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10230V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V N/A -- N/A -- N/A -- N/A --208V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10230V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10







400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

050D

055D

060D

070D

030D

035D

040D

045D


IM 1131 59

Electrical Data

Table 41: Connection Sizing - Multi-Point with optional External Overloads (continued)



208V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6230V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10

400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6230V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3380V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10




400-460V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6230V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 250A (1) 350 - #6380V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10208V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 400A (2) 500 - 3/0230V 380A (1) 500 - #4 250A (1) 350 - #6 380A (1) 500 - #4 400A (2) 500 - 3/0380V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 100A [1] (1) 1/0 - #10 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3208V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0230V 380A (1) 500 - #4 400A (2) 500 - 3/0 380A (1) 500 - #4 400A (2) 500 - 3/0380V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6

400-460V 175A (1) 2/0 - #14 250A (1) 350 - #6 175A (1) 2/0 - #14 250A (1) 350 - #6575V 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3 175A (1) 2/0 - #14 125A [1] (1) 3/0 - #3

130D

150D

170D

200D

080D

090D

100D

115D


60 IM 1131

Wiring
Wiring
Field Wiring, Power

WGZ chillers are supplied standard with compressor contactors and power terminal block, designed for multi-point power supply to the unit, no compressor circuit breakers. Available options are:

• Single-point connection to power block with compressor circuit breakers

• Single-point connection to disconnect switch with com-pressor circuit breakers

• High short circuit current rating with single-point dis-connect switch (Not available on 575V units)

• Multi-point connection to disconnect switch, no com-pressor circuit breakers

A factory installed control circuit transformer is standard. Optionally, a field-installed control power source can be wired to the unit.

Wiring and conduit selections must comply with the National Electrical Code and/or local requirements.

An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor, the trouble must be found and corrected. Tables in the Electrical Data section (page 39) give specific information on recommended wire sizes.

Unit power inlet wiring must enter the control box through the right side. A 7/8-inch pilot knockout is provided. (Refer to control panel picture Figure 30, page 62 for general location of power inlet.)

NOTE: Use only copper supply conductors. Terminations are sized for copper only.

Field Wiring, Control

A factory-mounted control transformer supplies the correct control circuit voltage.

The transformer power leads are connected to the power block PB1 or disconnect switch DS1.

Interlock Wiring, Condenser Pump Starter or Air Cooled Condenser Fan Starter

Provisions are made for interlocking a condenser pump starter, tower fans, a tower bypass valve, or up to eight air-cooled condenser fan contactors to be controlled by the MicroTech II unit controller. Condenser fan operation can also be controlled by pressure switches supplied with the condenser. Coil voltage must be 115 volts with a maximum of 20 VA.

An evaporator and condenser (water-cooled units only) flow switch is necessary on all units. It is also advisable to wire a chilled water pump interlock in series with the flow switch for additional freeze protection.

Control wiring must enter the control box through a 7/8-inch knockout provided on the panel upper left side.

Ambient Air Sensor

Units with a remote air-cooled condenser will have an outdoor air sensor furnished with the unit, inside the control panel and wired to the correct terminals. It must be installed outdoors in a location that will give the true outdoor temperature that the condenser coils will see. Splicing of the sensor lead may be required. The sensor must be installed for the unit to operate.

Optional Remote Interface Panel

The box containing the optional remote interface panel will have installation instructions, IOM- MT II Remote, in it.

IM 1131 61

Wiring

Figure 30: Control Panel Layout

(4) Compressor Circuit Breakers

(3) 120V/24V Transformers

LineV/120V Control Transformer

Control Transformer Fuses, Primary

Control Transformer Fuse, Secondary

Optional DisconneSwitch

MicroTech Controller

(2) Circuit Mechanical

Hi-Pressure Switch Relays

(4) Compressor Contactors

Grounding Lug

Location for Optional External Overloads

7/8-in. KO for control wiring

Switches

KO for Power Wiring

62 IM 1131

Warranty Registration Form (Scroll)
I. PRE START-UP PROCEDURE - refer to attached documentation.

II. PRE START-UP CHECKLIST YES NO A. Is any shipping damage visible?............................................................................................................................................. B. Is unit installed level?............................................................................................................................................................. C. Is unit positioned to provide adequate free area for service and operation? ........................................................................... D. Are fans properly aligned and turn freely? ............................................................................................................................. E. Has thermostat bulb been properly installed in the well? ....................................................................................................... F. Does electrical service correspond to unit nameplate? ........................................................................................................... Volts __ Hertz Phase G. Has unit been adequately grounded? ...................................................................................................................................... H. Has an adequate fused disconnect and fuses been installed? ..................................................................................................

Fuse Amp Rating ____________ I. Are all electrical power connections tight?............................................................................................................................. J. Have compressor crankcase heaters been operating for 24 hours prior to start-up? ............................................................... K. Are setscrews on all pulleys, bearings and fans tight?............................................................................................................ L. Are all service and liquid line valves open? ........................................................................................................................... M. Have all shipping hold down plates been removed?............................................................................................................... N. Does all field wiring conform to unit electrical diagram?....................................................................................................... O. Has a flow switch been installed per the IM bulletin?............................................................................................................ P. Does chiller and condenser water piping conform to the IM Bulletin?................................................................................... Q. Is wind impingement against the air cooled condenser a consideration?................................................................................ R. Description of unit location with respect to building structures; i.e., buildings, fences, walls, overhangs, other?

Description: _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________

Job Name: McQuay G.O. No.:

Installation Address:

City/State/Zip:

Purchasing Contractor:

City/State/Zip:

Unit Model No. Serial No.:

Compressor #1 Serial No.: Compressor #2 Serial No.:



Form # SF-99007 • Part #: 041541502-D 63


III. REFRIGERATION SYSTEM YES NO

A. Has all field piping been leak tested at 100 psig (690 kPa)?................................................................................................... B. Has system been properly evacuated and charged?................................................................................................................ C. Refrigerant R-___________ Circuit 1 __________ lbs. (kg) Circuit 2 _____________ lbs. (kg) D. Does piping to unit appear to be adequately sized and installed according to the IM bulletin?.............................................. E. Is a liquid line filter-drier installed in each circuit?................................................................................................................ F. Is level of oil in sightglass visible but not more than 1/2 glass with compressors running?................................................... G. Is a liquid line solenoid installed in each circuit? ................................................................................................................... H. Is expansion valve bulb properly installed and insulated?......................................................................................................

IV. DESIGN CONTROLS (From submittal)

A. CHILLER Water Pressure Drop: _______ psig (kPa) _________ Ft. (kPa) ________ gpm (lps) Water Temperatures: Entering ________ °F ( °C) Leaving __________ °F ( °C) B. CONDENSOR Water Pressure Drop: _______ psig (kPa) ________ Ft. (kPa) ________ gpm (lps) Water Temperatures: Entering ________ °F ( °C) Leaving __________ °F ( °C)

V. START-UP (Readings Must Be Taken At Full Load) YES NO A. Does unit start and perform per sequence of operation as stated in the IM bulletin?..................................................... B. Do condenser fans rotate in the proper direction?..........................................................................................................

MICROTECH STATUS CHECK (Each Reading Must be Verified With Field Provided Instruments Of Known Accuracy)

MicroTech Verification C. Water Temperatures: Leaving Evaporator.............................................................................. F (°C) F (°C) Entering Evaporator ............................................................................. F (°C) F (°C) Entering Condenser.............................................................................. F (°C) F (°C) Leaving Condenser............................................................................... F (°C) F (°C) D. Circuit #1Refrigerant Pressures: Evaporator _________ psig (kPa) ________ F ( °C) ________psig Minimum Condenser Pressure ________ psig (kPa) Maximum Condenser Pressure ________ psig (kPa) E. Circuit #2 Refrigerant Pressures: Evaporator ________ psig (kPa) ________ °F ( °C) psig Minimum Condenser Pressure _______ psig (kPa) Maximum Condenser Pressure _______ psig (kPa) F. Circuit #1 Refrigerant Temperatures: Saturated Evaporator Temperature....................................................... F (°C) F (°C) Suction Line Temperature.................................................................... F (°C) F (°C) Suction Superheat................................................................................. F (°C) F (°C) Saturated Condenser Temperature ....................................................... F (°C) F (°C) Condenser Approach ............................................................................ F (°C) F (°C) Liquid Line Temperature ..................................................................... F (°C) F (°C) Subcooling ........................................................................................... F (°C) F (°C) G. Circuit #2 Refrigerant Temperatures: Saturated Evaporator Temperature.......................................................________F (°C) F (°C) Suction Line Temperature....................................................................________F (°C) F (°C) Suction Superheat.................................................................................________F (°C) F (°C) Saturated Condenser Temperature .......................................................________F (°C) F (°C) Condenser Approach ............................................................................________F (°C) F (°C) Liquid Line Temperature .....................................................................________F (°C) F (°C) Subcooling ...........................................................................................________F (°C) F (°C) H. Outdoor Air Temperature ............................................................................................................________F (°C) F (°C)

64 Form # SF-99007 • Part #: 041541502-D


I. Does the system contain glycol? ..................................................................................................................................... Percentage by weight __________ or by volume __________

J. If the chilled water system includes glycol, have the freezestats been adjusted lower to meet actual job requirements? Note: See installation bulletin for low temperature or ice bank applications.

K. Waterside Pressure Drop:

Chiller: psig (kPa) Ft. (kPa) gpm (lps)

Condenser: psig (kPa) Ft. (kPa) gpm (lps)

L. System Oil Pressure:

Compressor #1 _______ psig (kPa) Compressor #3 ________ psig (kPa) Compressor #5 ________ psig (kPa)

Compressor #2 _______ psig (kPa) Compressor #4 ________ psig (kPa) Compressor #6 ________ psig (kPa)

M. Unit Voltage Across Each Phase: V V V

N. Unit Current Per Phase: amps amps amps

O. Compressor Current Per Phase:

Compressor #1: Amps Amps Amps



Compressor#4: Amps Amps Amps



VI. CONTROL CHECK AND SETPOINT VERIFICATION / STANDARD UNIT SETPOINT MICROTECH SETPOINTS MICROTECH STANDARD

A. Leaving Evaporator ........... ............................................................................................................. ________F (°C) _______ F (°C) B. Reset Leaving .................... ............................................................................................................. F (°C) F (°C) C. Reset Signal....................... ............................................................................................................. ___________ma D. Reset Option ____________ E. Maximum Chilled Water Reset ....................................................................................................... F (°C) F (°C) F. Return Setpoint.................. ............................................................................................................. F (°C) G. Maximum Pulldown .......... ............................................................................................................. F (°C) H. Control Band ..................... ............................................................................................................. F (°C) F (°C) I. Interstage Delay................. ............................................................................................................. sec. ________ sec. J. Start-to-Start Delay............ ............................................................................................................. min. K. Stop-to-Stop Delay ............ ............................................................................................................. ________min. L. Minimum Lift Pressure...... ............................................................................................................. ____ psig (kPa) M. Deadband........................... ............................................................................................................. ____ psig (kPa) N. Stage Up Error ................... ............................................................................................................. ____ psig (kPa) O. Stage Down Error .............. ............................................................................................................. ____ psig (kPa)

ALARM SETPOINTS MUST BE VERIFIED WITH INSTRUMENTS OF KNOWN ACCURACY

P. Low Pressure Cut-In ........ ............................................................................................................. ____ psig (kPa) ____ psig (kPa) Q. Low Pressure Cut-Out...... ............................................................................................................. ____ psig (kPa) ____ psig (kPa) R. Refrigerant Freezestat....... ............................................................................................................. ____ psig (kPa) ____ psig (kPa) S. Chilled Water Freezestat .. ............................................................................................................. ____ psig (kPa) ____ psig (kPa) T. Freezestat Time Delay...... ............................................................................................................. _________sec. _________sec. U. High Pressure Cut-Out...... ............................................................................................................. ____ psig (kPa) ____ psig (kPa) V. Unit Type = _____________________ W. Number of Compressors = __________ X. Number of Stages = _______________ Y. Number of Fan Stages = ___________ Z. IDENT = _______________________

Form # SF-99007 • Part #: 041541502-D 65


VII. FOR HEAT RECOVERY CHILLERS ONLY (Must Be Taken At Full Load) A. Place unit in heat recovery mode. B. Waterside Pressure Drop: ________ psig (kPa) __________ Ft. (kPa) __________ gpm (lps) C. Waterside Temperatures: _________ Inlet __________ Outlet D. Head Pressure: Circuit #1 __________ psig (kPa) Circuit #2 _________ psig (kPa) E. Suction Pressure: Circuit #1 _________ psig (kPa) Circuit #2 _________ psig (kPa) F. Compressor Current Per Phase: Compressor #1 __________ AMPS ___________ AMPS __________ AMPS Compressor #2 __________ AMPS ___________ AMPS __________ AMPS Compressor #3 __________ AMPS ___________ AMPS __________ AMPS Compressor #4 __________ AMPS ___________ AMPS __________ AMPS

VIII. GENERAL

A. Are all control lines secure to prevent excess vibration and wear? ........................................................................................ B. Are all gauges shut off, valve caps and packings tight after startup? .....................................................................................

Performed By: Title:

Company Name: _____________________________________________________________________________________________________

Address: ___________________________________________________________________________________________________________

City/ State/ Zip Code: _________________________________________________________________________________________________

Telephone Number: ______________________________________ Modem Number: _____________________________________

Signature: Date:

Contractor's Signature:

RETURN COMPLETED FORM TO: McQUAY INTERNATIONAL, WARRANTY DEPARTMENT, PO BOX 2510, STAUNTON, VA 24402

66 Form # SF-99007 • Part #: 041541502-D

© 2012 McQuay International • www.daikinmcquay.com • 800-432-1342 03/12

Daikin McQuay Training and Development

Now that you have made an investment in modern, efficient Daikin McQuay equipment, its care should be a high priority. For training information on all Daikin McQuay HVAC products, please visit us at www.daikinmcquay.com and click on training, or call 540-248-9646 to speak to the Training Department.

Warranty

All Daikin McQuay equipment is sold pursuant to its standard terms and conditions of sale, including Limited Product Warranty. Consult your local Daikin McQuay Representative for warranty details. Refer to Form 933-43285Y. To find your local Daikin McQuay Representative, go to www.daikinmcquay.com.

This document contains the most current product information as of this printing. For the most up-to-date product information, please go to www.mcquay.com.



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